Chemical Engineering

Basic Chemical Engineering

Nature of Industrial Process

There are two categories for industrial (chemical) processes.

Batch or cycle processes
Ongoing procedure or continuous process

Batch or cycle processes

Batch processing is the method in which raw materials are continuously supplied into the machinery.

This method involves loading raw materials and drawing manufacturing step by step.

When a minimal amount of a product is required, this procedure is used.

This method is more adaptable than a continuous one.

In batch processes, capital investment is minimal.

Greater operating costs result from the necessity for more staff due to the manual handling of the material.

Not automated

Product quality varies from batch to batch.

Examples

Batch production is most frequently used in bakeries, the production of athletic footwear, pharmaceutical chemicals, soap, water purification, inks, paints, and adhesives.

Both positive and negative aspects

Batch production has a number of benefits, including the ability to lower upfront capital expenditure (the cost of setting up the machines). For small enterprises who lack the resources to operate continuous manufacturing lines, batch production can be advantageous. A producer may stop manufacturing without suffering significant losses if a merchant purchases a batch of a product that does not sell. A factory that produces seasonal goods, a test run for production, or goods with a large profit margin can all benefit from batch manufacturing.

Additionally, batch production has several limitations. Batch production has drawbacks because it requires stopping, reconfiguring, and testing of equipment before the next batch can be created.

Ongoing procedure or continuous process

Continuous process refers to a method in which raw materials are continuously fed into a device.

Raw materials are fed into this process, and the product is continuously drew out.

When a high-quality product is required, this technique is used.

Compared to batch processes, continuous processes are less flexible.

When compared to a batch process, operating costs are minimal but capital expenditure is expensive.

Being automatic

Consistent product quality

A flow production technique called continuous production is used to continuously create, produce, or process materials. Because the materials dry bulk or fluids that are being processed are continuously in motion, experiencing chemical reactions, or undergoing mechanical or thermal treatment, continuous production is also known as a continuous process or a continuous flow process.

Continuous operation often refers to running continuously 24 hours a day, seven days a week with only irregular maintenance breaks, like semi-annual or annual. Some chemical factories have the ability to run continuously for up to two years. The lifespan of a blast furnace is four to ten years.

Here are a few typical continuous processes: