Handbook of Batch Process Design

Batch processes are used to manufacture many fine organic chemicals, and as such they can be considered to underpin much of the modern chemical industry. Despite widespread use and a consequent huge contribution to wealth creation, batch processes have attracted limited attention outside the user industries. Batch chemicals processing uses a number of core techniques and technologies, such as scheduling and sequence control, agitation and batch filtration. The combination of these technologies with often complex chemistry, the multi-purpose nature of much of this type of plant, the distinctive safety and environmental issues, and a fast moving commercial environment makes the development of a successful batch process a considerable challenge for the chemist or engineer. The literature on the topics covered in this book is fragmented and often not easily accessible, so this handbook has been written to address this problem and to bring together design and process analysismethods in the core areas of batch process design. By combining the science and pragmatism required in the development of successful batch processes this new book provides answers to real problems in an accessible and concise way. Written by an international team of authors drawn from industry, consulting and academe, this book is an essential part of the library of any chemist, technologist or engineer working on the development of new or existing batch processes.

Table of Contents:
1 Chemicals manufacture by batch processes.- 1.1 Introduction.- 1.2 Industrial background.- 1.3 Reasons for the use of batch processing.- 1.4 Batch process design for fine and speciality chemical production.- 1.5 Plant design.- 1.6 Summary.- References.- 2 Scheduling and simulation of batch processes.- 2.1 Introduction.- 2.2 Batch process features.- 2.3 The scheduling problem.- 2.4 Batch process simulation.- 2.5 Design implications.- References.- 3 Solvents in chemicals production.- 3.1 Introduction.- 3.2 Solvent properties.- 3.3 Solubility.- 3.4 Solvent effects on reactions.- 3.5 Solvent recovery.- 3.6 Solvent destruction.- 3.7 Conclusion.- 3.8 Nomenclature.- References.- 4 Agitation.- 4.1 Agitator selection.- 4.2 Calculation of agitator power, discharge flow and mixing time.- 4.3 Power and circulation in non-Newtonian fluids.- 4.4 Design to disperse solid particles.- 4.5 Design for two or more liquid phases.- 4.6 Design for dispersing gas.- 4.7 Design for heat transfer.- 4.8 Nomenclature.- References.- 5 Mixing and the selectivity of fast chemical reactions.- 5.1 The problem.- 5.2 Mixing mechanisms and modelling.- 5.3 Applications.- 5.4 Extensions.- 5.5 Concluding remarks.- 5.6 Nomenclature.- References.- 6 Batch filtration of solid—liquid suspensions.- 6.1 Introduction.- 6.2 Filtration process fundamentals.- 6.3 Batch operated filtration machinery.- 6.4 Nomenclature.- References.- 7 Design and engineering of a batch plant.- 7.1 Introduction.- 7.2 Project definition.- 7.3 Project strategy.- 7.4 Project organization.- 7.5 ‘Fast track’ projects.- 7.6 Regulations and other controls.- 7.7 Design techniques.- 7.8 Layout considerations.- 7.9 Plant relocation/reuse of existing equipment.- 7.10 Modular plant.- 8 Control.- 8.1 Introduction.- 8.2 Control of continuous processes.- 8.3 Control of batch processes.- 8.4 Batch control systems — structure and functions.- 8.5 Computer control.- 8.6 Procedural control.- 8.7 Acknowledgements.- References.- 9 Hazards from chemical reactions and flammable materials in batch reactor operations.- 9.1 Introduction.- 9.2 Hazard identification.- 9.3 Chemical reaction hazards.- 9.4 Fire and explosion hazards.- 9.4 Conclusions.- References.- 10 Environmental protection and waste minimization.- 10.1 Introduction.- 10.2 Batch reactor waste minimization.- 10.3 Equipment for the production of solid products.- 10.4 Fugitive and other minor emissions.- 10.5 Cleaning wastes.- 10.6 Waste treatment and solvent management.- 10.7 Environmental protection.- 10.8 Conclusions.- References.- 11 Future developments in batch process design and technology.- 11.1 Influences for and against change.- 11.2 New technologies.- 11.3 New processes.- 11.4 New design methods.- 11.5 New skill requirements.- References.