(িবষয়িভি ক অংশ)

Applied Chemistry
 Mentor

Md. Raihan
Lecturer, Chemistry
Patuakhali Govt. College, Patuakhali
38th BCS General Education Cadre
 Today’s Topic:
Lecture: 01
1. Importance of Chemical technological processes
2. Development of Chemical technology
3. Classification of Chemical technological processes.
4. Techno-economic feasibility study of a project.
5. Site selection for chemical industry.
6. Unit process and unit operation.
7. Design and implementation of a chemical project.
8. Fundamentals of Chemicals Industries.
9. Importance of Chemical Technology for Industry.
10. Pre-conditions for setting up of a new Chemical Industry.
11. Problems of Chemical Process Industries in Bangladesh
and their solutions.
** What is Chemical Technology?
Chemical Technology is a branch of science
and engineering that focuses on the
design, optimization, operation and
improvement of processes that involve
chemical reactions and transformations.
It integrates principles of chemistry,
physics, biology, and engineering to
develop efficient and sustainable methods
for producing materials, chemicals, fuels,
pharmaceuticals, and other products used
in daily life.
Key areas of Chemical Technology:-
Chemical Process Design

Catalysis and Reaction Engineering

Separation Processes

Materials Development

Environmental Technology

Energy Technology
Importance of chemical technology for industry

Development of New Products

Optimized Production Processes
Sustainability & Environmental Protection
Energy Efficiency
Quality Improvement
Economic Growth
Enabling Innovations
Renewable Resources & Circular Economy
Applications in Industries:
•Pharmaceuticals: Drug development and large-
scale synthesis of medicines.
•Petrochemicals: Refining oil and gas and
producing fuels, plastics, and lubricants.
•Food Industry: Enhancing food preservation,
flavoring, and processing.
•Agriculture: Manufacturing fertilizers, pesticides,
and soil conditioners.
•Materials Science: Developing polymers,
composites, and nanomaterials.
 Historical Milestones in the
Development of Chemical Technology
• Metallurgical techniques for smelting metals like
copper and iron.
• Production of glass and ceramics.
Ancient • Fermentation processes for alcohol and vinegar.
Period

• Focus on mystical and experimental chemistry.

Alchemical • Development of apparatus & processes like distillation & sublimation.
Period • Emergence of basic chemical compounds, such as acids and salts.
(Middle
Ages)
• Shift from alchemy to systematic experimentation and theory.
• Significant Advancements: Lavoisier's discovery of role of oxygen in
Early combustion (1770s).
Modern • Early development of industrial chemical processes, such as sulfuric
Chemistry acid production using lead chambers
(16th–18th
Century)
 Historical Milestones in the
Development of Chemical Technology
• Chemical technology began to scale up for industrial
purposes.
• Leblanc process for producing soda ash from salt.
Industrial • Solvay process as a more efficient alternative to the
Revolution Leblanc process.
(18th–19th) • Development of synthetic dyes and fertilizers.
• Advancements in thermodynamics, reaction kinetics, and material science.
• Haber-Bosch process for ammonia synthesis, revolutionizing agriculture with
synthetic fertilizers.
20th • development of fluid catalytic cracking (FCC) helped with Petrochemical
Century industry emergence for producing plastics, fuels & synthetic fibers.
• Polymer technology leading to materials like nylon, Teflon, and polyethylene.
• Emphasis on sustainability, efficiency, and advanced technologies.
• Green chemistry principles to reduce waste and environmental impact.
Late 20th • Biochemical processes, including enzyme catalysis & fermentation for biofuels
and Early & pharmaceuticals.
21stCentur • Development of nanotechnology for precision material design.
y • Advancements in renewable energy tech like H production & solar cells.
Classification of Chemical Technological Processes
Based on the Nature of Transformation
1. Physical Processes:- Involve changes in physical state or
composition without altering the chemical identity.
➢ Examples: • Distillation • Filtration • Crystallization
• Evaporation
2. Chemical Processes:- Involve chemical reactions that
transform reactants into new products with different chemical
compositions.
➢ Examples: • Combustion • Polymerization • Neutralization
• Oxidation/Reduction

3. Biochemical Processes:- Utilize biological systems, such

as enzymes or microorganisms, to carry out transformations.
➢ Examples: • Fermentation • Enzymatic hydrolysis
• Bioconversion
Classification of Chemical Technological Processes
Based on Raw Materials and Products
1. Petrochemical Processes:- Use crude oil and natural gas
as raw materials to produce fuels, plastics, and other chemicals.
Examples: • Cracking • Reforming • Hydrocracking

2. Inorganic Processes:- Focus on the production of

inorganic compounds.
Examples: • Haber-Bosch process (ammonia production)
• Contact process (sulfuric acid production) • Electrolysis of
brine (chlorine and sodium hydroxide production)

3. Organic Processes:- Produce organic chemicals and

materials from hydrocarbons or biomass.
Examples: • Alcohol fermentation • Production of polymers
like polyethylene • Synthesis of pharmaceuticals
Classification of Chemical Technological Processes
Based on the State of Reactants and Products
1. Homogeneous Processes:- Reactants and catalysts are in
the same phase (e.g., liquid or gas).
Examples: Gas-phase reactions in the production of nitric acid.
2. Heterogeneous Processes:- Reactants and catalysts are in
different phases.
Examples: Catalytic cracking (gas-liquid-solid phase interaction)
Based on Mode of Operation
1. Batch Processes:- Materials are added, processed, and
removed in discrete steps. Suitable for small-scale production and
flexibility.
➢ Examples: Production of specialty chemicals or pharmaceuticals.
2. Continuous Processes:- Reactants are continuously fed
into the system, and products are continuously removed. High
efficiency and consistent quality.
➢ Examples: Petroleum refining, Continuous polymerization.
 TECHNO ECONOMIC FEASIBILITY STUDIES
Objective of Techno-Economic Feasibility Studies/ Detailed Project
Reports ( কে র কািরগির অথৈনিতক স াব তা) is to determine the
technical feasibility and financial viability of the project, assess the
risks associated with the project and enumerate imminent actions
that are required to be taken.
Coverage:
Based on the clients requirement, Techno-Economic Feasibility
Studiescover the following :
Markets: It covers estimated future sales revenue of the
project based on estimated sales volumes and price.

Raw Materials & Fuel: It estimates the adequacy of the

quality and quantity of the raw materials and fuel for the project,
make an estimate of its cost.

Logistics: Inbound and outbound logistics and logistics

planning.
TECHNO ECONOMIC FEASIBILITY STUDIES
Project Technical Concept: This is core deliverable of the
project and covers plant capacity, equipment sizing, storages, plant
auxiliaries, system engineering, electrical engineering, civil
engineering, Control & Automation engineering, Quality Control &
Assurance, Captive Power Plant and Waste Heat recovery system
(WHR) based on the project requirement.

Environment: Applicable Regulatory Framework and

Environmental Impact of Project.

Plant Siting, Location & Infrastructure: It assesses the

existing infrastructure and actions required to develop the
infrastructure necessary to set up the project.
It also covers:-
Operating Cost: It covers cost of raw material, utilities, overheads.
Financial Appraisal: It covers project profitability, IRR, NPV, payback,
Risks & Mitigation.
TECHNO ECONOMIC FEASIBILITY STUDIES

Methodology: Broad methodology of execution involves:

► Data collection
► Data analysis
► Report and Project formulation\

Benefits:
It helps a client make an investment decision based on:
► Technical feasibility of the project.
► Financial viability of the project.
► The risks associated with the project.
► Actions required for risk mitigation.
Site selection for chemical industry
Site selection for chemical industry
Site selection for chemical industry
Example of Unit operation
Example 1 – Distillation of Methylene Di Chloride with
water
Explanation – In a process, the separation of Methylene
Di Chloride with water using a liquid-liquid separation
technique can be called a unit operation. Only separation
is taking place which will be done based on density
difference. This is a physical change and no chemical
reaction taking place. So it considered a unit operation.
Example 2 – Distillation of acetone and water
Explanation – The distillation of acetone from the water is
an example of unit operation. In this process, acetone is
separated and that is due to boiling point difference. This
is also a physical change and no chemical reaction is
carried out. Hence distillation is a unit operation.
Classification of Unit Operation
1. Material handling, 3. Mass transfer
transportation / operations
Fluid flow process Evaporation
Pumping Distillation
Compression Absorption
fluidization Extraction
2. Mechanical unit leaching.
operations 4. Heat transfer
Size reduction operations
Size enlargement conduction
Mixing, agitation, convection
blending, etc radiation
Example of Unit process
Example 1 – Electrolysis of sodium chloride solution
Explanation – Here, electrolysis of NaCl is done and
sodium hydroxide is produced. In this reaction, a
decomposition reaction takes place. Hence, this is a unit
operation.
Example 2 – Production of Hydrogen
Explanation – Hydrogen is produced using a very popular
method i.e. Steam-methane reforming reaction. In this
method, methane reacts with steam under 3–25 bar
pressure in the presence of a Nickel catalyst to produce
hydrogen. In this process, a chemical reaction under
pressure and temperature is conducted to react Methane
with steam and generate Hydrogen. As the reaction is
conducted, this process comes under the unit process.
Design and implementation of a chemical project

A chemical project design and implementation

involves defining objectives, identifying reactions,
designing reactors and separation processes, and
optimizing the overall process for efficiency and safety.

This includes developing a process flow

diagram, equipment sizing and selection, material and
energy balances, and control system design, waste
treatment systems, process simulation, and energy
integration.
Here's a more detailed breakdown:
Design and implementation of a chemical project
1. Project Definition and Conceptualization:
Define the Objective: Clearly state the purpose of the project, such as
creating a new product or improving an existing process.
Identify Reactions: Determine the chemical reactions involved and their
stoichiometry.
Gather Information: Collect data on reaction kinetics, thermodynamics,
and physical properties of reactants and products.
Define Scope: Establish the boundaries of the project, including
production rate, purity, and any constraints.
2. Process Design:
Develop a Process Flow Diagram (PFD): Create a visual representation of
the process, including all equipment & flow paths.
Equipment Selection and Sizing: Choose appropriate equipment like
reactors, distillation columns, heat exchangers, and pumps based on
process requirements.
Material and Energy Balances: Calculate the flow rates & compositions of
materials throughout the process, as well as energy requirements.
Process Optimization: Use simulation software to optimize parameters like
temperature, pressure, and flow rates for maximum efficiency and yield.
Design and implementation of a chemical project
3. Control System Design:
Develop Control Strategies: Design control loops to maintain desired
process conditions, such as temperature, pressure, and flow rate.
Select Control Devices: Choose appropriate sensors, transmitters,
and control valves.
Implement a control system: Integrate the control system with the
process equipment.
4. Safety Analysis and Risk Assessment:
Identify Hazards: Identify potential hazards associated with the
process, such as flammability, toxicity, and reactivity.
Assess Risks: Evaluate the likelihood and severity of each hazard.
Implement Safety Measures: Implement appropriate safety
measures, such as emergency shut-off systems, relief valves, and
ventilation.
5. Detailed Engineering and Implementation:
Equipment Design: Design individual pieces of equipment in detail,
including mechanical and structural aspects.
Design and implementation of a chemical project
Piping and Instrumentation Diagram (P&ID): Create a detailed diagram
showing all equipment, piping, and instrumentation.
Procurement and Construction: Procure materials and equipment, and
oversee the construction of the plant.
Commissioning and Start-up: Test and verify the operation of the plant
before full-scale production.
6. Project Management:
Develop a Project Plan: Establish timelines, budgets, & resource allocation.
Manage Communication: Keep all stakeholders informed of project progress.
Ensure Quality Control: Implement quality control measures throughout the
project lifecycle.
7. Sustainability Considerations:
Minimize Waste: Design processes that minimize waste generation and
promote recycling.
Reduce Energy Consumption: Optimize processes to reduce energy
consumption and greenhouse gas emissions.
Use Sustainable Materials: Select materials that are environmentally
friendly and can be recycled.
FUNDAMENTALS OF CHEMICALS INDUSTRIES
The chemical industry is a foundational sector in our economy and
society. They act as essential enablers to other industries providing
everything from basic chemicals, to high-value specialty chemicals.

Ethylene, for instance, is a critical component used extensively by

the automotive, construction, and electronics sectors.

The chemical industry is an essential industry with a part to play in

roughly 96% of all manufactured goods across the world. This
industry is foundational for other industries like automotive,
healthcare, agriculture, and construction.

We can categorize the Chemical Industry into five sub categories

based on the products they manufacture: Basic Chemicals,
Agrochemicals, Specialty Chemicals, Industrial Gases, and
Downstream Industries
FUNDAMENTALS OF CHEMICALS INDUSTRIES
FUNDAMENTALS OF CHEMICALS INDUSTRIES
IMPORTANCE OF CHEMICAL TECHNOLOGY FOR INDUSTRY
Chemical technology bridges the gap between laboratory
scale chemistry and industrial production. It’s importance
are as follows:
1. Foundational for Many Industries:
Manufacturing: provides the building blocks for
countless products, from plastics and fibers to specialized
materials used in various manufacturing processes.
Pharmaceuticals: producing medicines, ensuring the
availability of life-saving drugs and treatments.
Food Production: involved in food processing,
preservation, and development of fertilizers and pesticides.
Energy: refining crude oil, developing new energy
storage solutions and exploring alternative energy sources.
Environmental Sustainability: sustainable solutions
for pollution control, waste management,resource recovery.
IMPORTANCE OF CHEMICAL TECHNOLOGY FOR INDUSTRY

2. Driving Innovation and Progress:

Process Optimization: improve chemical processes,
making them more efficient, cost-effective, and
environmentally friendly.
New Materials: developing new materials with
unique properties, pushing the boundaries of what's
possible in various applications.
Product Development: creation of new and
improved products across numerous sectors, from
consumer goods to advanced technologies.
3. Economic Impact:
Wealth Creation: economic growth, generating
significant revenue and creating numerous jobs.
IMPORTANCE OF CHEMICAL TECHNOLOGY FOR INDUSTRY
Innovation and Competitiveness: competitive
industries in the global market, fostering economic
development and progress.
Resource Management: optimizing resource
utilization, minimizing waste and promoting sustainable
practices.
4. Specific examples:
Mineral Fertilizers: that significantly increase crop
yields and improve food production.
Pesticides and Herbicides: protecting crops from
pests and weeds, ensuring food security.
Polymers and Plastics: production of a wide range
of polymers and plastics, which are used in countless
applications.
Pre-conditions for setting up of a new
Chemical Industry.
1. Market and Feasibility Study:
Market Analysis:
(i) understand the demand for the intended chemical
products.
(ii) identify potential customers.
(iii) assess the competitive landscape.
(iv) understand existing market gaps & opportunities.
Raw Material Availability:
(i) reliable and cost-effective supply of necessary raw
materials for the intended industry.
(ii) sourcing from within the country or importing.
(iii) transportation and storage factors.
End-Use Applications: targeting the right market segments
and tailoring production accordingly.
 Pre-conditions for setting up of a new
Chemical Industry.
Technological Suitability: technological
requirements for production:- equipment, processes, and
expertise.
2. Legal and Regulatory Framework:
Permits and Licenses: permits and licenses from
relevant government authorities (e.g., environmental
protection agency, health and safety agencies)
Compliance with Regulations: all applicable
environmental, safety & labor regulations. must avoid legal
issues and penalties.
3. Infrastructure and Resources:
Raw Material Supply: reliable supply chains for raw
materials, transportation & storage infrastructure.
 Pre-conditions for setting up of a new
Chemical Industry.
Site Selection: suitable location with access to
transportation, utilities (water, power, gas), and waste
disposal facilities.
Skilled Labor: availability of skilled workforce for
various roles within the chemical industry.
Utilities and Services: reliable access to essential
utilities like water, electricity, gas & waste management.
4. Environmental Sustainability:
Environmental Impact Assessment: evaluate the
potential environmental effects of the industry and
develop mitigation strategies.
Waste Management: effective waste management
systems to minimize environmental pollution and comply
with regulations.
Problems of Chemical Process Industries in
Bangladesh and their solutions
Environmental Concerns:
Problem: Chemical waste management and pollution
particularly in leather & textile industries.
Solution: (i) Implement advanced wastewater treatment
technologies.
(ii) establish central effluent treatment plants
(ETPs) in industrial areas.
(iii) promote the use of eco-friendly chemicals.
Reliance on Imports:
Problem: Dependence on imported raw materials and
hence making it vulnerable to global price fluctuations
and supply chain disruptions.
Solution: (i) Encourage local production of essential
chemicals and raw materials.
Problems of Chemical Process Industries in
Bangladesh and their solutions
(ii) explore alternative sourcing.
(iii) develop domestic industries to reduce import
dependency.
Inadequate Infrastructure:
Problem: (i) Limited infrastructure
(ii) inadequate utility services like water & electricity.
Solution: (i) Invest in improving infrastructure
(ii) ensure a stable supply of essential resources.
Safety Issues:
Problem: lack of proper safety protocols and regulations.
Solution: (i) Implement strict safety regulations.
(ii) provide regular safety training to workers.
(iii) ensure that all chemical plants adhere to safety
standards and proper enforcement of relevant laws.
 Sample questions
1. Which innovation marked the upshift in chemical industry in the 18th
century?
•A) Inventing the first synthetic dye
•B) The Leblanc process for soda ash production
•C) The Haber–Bosch ammonia synthesis
•D) Development of celluloid plastics
Answer: B – The Leblanc process (1791) enabled large-scale production
of soda ash (sodium carbonate), essential for glass, textiles, soap, and
paper industries

2. The Leblanc process for soda ash production is replaced by a more

efficient alternative. Which is?
•A) Solvey process.
•B) Dual-process.
•C) electrolytic process.
•D) Solution Mining process.
•Answer: A – The Solvay process came as a more efficient and cleaner
method for producing soda ash and became a viable alternative to the
Leblanc process in the 1860s.
 Sample questions
3. Distillation process developed in which Period?
A. Ancient period.
B. Alchemical Period.
C. Early modern Period.
D. Industrial Period.
Answer: B – Development of apparatus & processes like distillation
& sublimation happened in Alchemical Period.

4. During the mid-20th century, which process revolutionized

petroleum refining?
A) Leblanc process
B) Synthetic dye manufacturing
C) Fluid catalytic cracking (FCC)
D) Solvay soda process
Answer: C – The development of fluid catalytic cracking (FCC) in
1942 dramatically increased high-octane fuel production
 Sample questions
5. Which of the following best describes a Unit Operation?
A) An irreversible chemical reaction
B) A process involving only physical changes
C) A reaction occurring in the presence of a catalyst
D) A sequence of multiple operations
Answer: B- Unit operations involve only physical transformations
(e.g., distillation, evaporation) without altering chemical
composition.

6. What is a defining characteristic of a Unit Process?

A) It may be reversible or irreversible
B) It involves purely mechanical changes
C) It entails a chemical reaction
D) It excludes reactor design considerations
Answer: C- Unit processes involve chemical changes-transformations
that alter molecular structure (e.g., oxidation, nitration).
 Sample questions
7. Which of these is an example of a Unit Operation?
A) Hydrogenation
B) Nitration
C) Distillation
D) Sulfonation
Answer: C- Distillation is a classic unit operation involving physical
separation without chemical reaction.

8. An example of a Unit Process is:

A) Drying
B) Extraction
C) Esterification
D) Filtration
Answer: C- Esterification is a chemical reaction—making and
breaking bonds—thus a unit process
 Sample questions
9. What is the main difference between unit operations and unit
processes?
A) Unit operations are industry-specific; unit processes are universal
B) Unit operations involve chemical changes; unit processes involve
physical changes
C) Unit operations are reversible; unit processes are irreversible
D) Unit operations involve physical changes; unit processes involve
chemical changes
Answer: D- Unit operations change the physical state of materials;
unit processes involve chemical transformations.

10. What percentage of all manufactured goods relies on the

chemical industry?
A) 50% B) 75% C) 96% D) 86%
Answer: C – The chemical industry supports approximately 96% of
worldwide manufactured goods.
 Sample questions
11. Which of the following is not one of the five subsegments of the
chemical industry?
A) Basic Chemicals B) Specialty Chemicals
C) Industrial Gases D) Pharmaceuticals
Answer: D – The recognized subsegments include Basic Chemicals,
Agrochemicals, Specialty Chemicals, Industrial Gases, and
Downstream Industries.

12. A process flow diagram (PFD) is primarily used to:

A) Detail piping line classes
B) Show all instrumentation used in a plant
C) Represent the general flow of plant process and equipment
D) Illustrate electrical wiring layouts
Answer: C – A PFD highlights the relationships between major
equipment and flow directions, without including minor piping or
control details.
 Sample questions
13. The concept of unit operations categorizes process steps by their
function. Which of the following is not a category of unit
operations?
A) Fluid flow processes
B) Heat transfer processes
C) Economic optimization processes
D) Mass transfer processes
Answer: C – Categories include fluid flow, heat transfer, mass
transfer, thermodynamic, and mechanical processes—but not
“economic optimization”