Course No.

: ACCE 1101
Course Title: CHEMICAL ENGINEERING –FUNDAMENTAL AND PROCESS CALCULATION

Chapter 1: Introduction to Chemical Technology

and Chemical Process Industries

Professor Dr. Md. Minhaz-Ul Haque

Dept. Applied Chemistry and Chemical Engineering
Islamic University, Kushtia

August 13, 2025 Kushtia

 Chapter -1

Introduction to Chemical Engineering and Chemical Process Industries:.

History and Development of Science and Technology,
Chemical Engineering, Chemical technology,
Study of Chemical process Industries,
The job of chemical engineer, Development of studies,
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh,
Future prospect of different types of Chemical industries in Bangladesh,
Unit process, Unit operation, Flow diagram, Symbol of some accessories.
Reference Books
 Chemical Engineering

Chemical engineering is a branch of engineering, dealing with processes in which materials undergo
changes in their physical or chemical state. The changes may concern size (for example in crushing or
milling of solid materials), energy content (as in heating, cooling, or evaporation), composition (as in
separations by, e.g. distillation, or membrane separations, as well as in chemical reactions) and/or other
application properties (e.g. flowability of powders and granulates, stability of emulsions).

The constitution of the American Institute of Chemical Engineers (A.I.Ch.E.) define chemical
engineering as- that branch of engineering which deals with the application of the principles of the
physical sciences, together with the principles of economics and human relations, to fields that pertain
directly to processes and process equipments in which matter is treated to effect a change in state,
energy content and composition. The definition is very broad, briefly, chemical engineering is the
development, design, and operation of various kinds of processes. Most chemical engineering activities,
in one way or another, are process oriented.

Chemistry: the scientific study of the structure of substances, how they react when combined or in
contact with one another, and how they behave under different conditions.

Engineering: the activity of applying scientific knowledge to the design, building and
control of machines, roads, bridges, electrical equipment, etc.
 Chemical process Industry

Products of the chemical process industry are used in all areas of every day life.
The raising of food plants and animals requires chemical fertilizers, insecticides, food supplements, and
disinfectants.
Many building materials have been chemically processed, for example, metals, concrete, roofing
materials, paints, and plastics.
Clothing utilizes many synthetic fibers and dyes.
Transportation depends upon gasoline and other fuels.
Written communication uses paper and printing ink;
and electronic communication requires many chemically processed insulators and conductors.
The nation's health is maintained by drugs and pharmaceuticals, soaps and detergents, insecticides and
disinfectants —all products of the chemical process industry.
In addition, many chemicals never reach the consumer in their original form but are sold within the
industry for further processing or use in the production of other chemicals for consumer use.
It is often said that the chemical industry is its own best customer.
 Chemical process Industry

Any definition or description of the chemical process industry is bound to be incomplete. Most processes in the
chemical industry involve a chemical change. The term "chemical change" should be interpreted to include not
only chemical reactions but also physicochemical changes, such as the separation and purification of the
components of a mixture.
Perhaps a satisfactory definition of a chemical process industry is "an industry whose principal products are
manufactured by processes based upon the chemical and physical principles included in the field of chemical
engineering."

As an example, the manufacture of the plastic polyethylene, using ethylene produced from petroleum or natural
gas, involves a chemical process. On the other hand, the molding and fabrication of the resulting plastic resin
into final shapes for consumer products would not be considered part of the chemical process.
 Chemical process Industry

The activities of chemical process industries are divided into two parts,
- one is synthesis of new products and
- the other is separation or purification of synthesized products.
A manufacturing unit is concerned with industrial processes in which raw materials are
processed or separated into useful products. In some case, the products themselves may serve
as the starting materials for other industries or product, in other words they may not be the
end products and are called as the intermediates.

Chemical industries are basically divided into two groups.

- First which produces simple compounds from the locally available large amount of raw
materials usually they are very large industries and the product manufactured are purified to
the extent that they can be used as raw material for other industries or they are directly
marketed as a consumer goods. In general they are heavy chemical industries.
- On the other hand certain industries deal with speciality chemicals and they are making
small quantity of product having better quality which is sold into market as finished good.
They are called as fine chemical industries.
Classification of chemical process industries
The materials used or produced in the chemical industries are classified in the following manner.
1. Quantity of production and consumption
a) Heavy chemicals
Those dealt in large quantity normally crude or less purified chemicals. e.g. Mineral acid, NaOH,
Na2CO3 etc.
b) Fine chemicals
They are completely purified substances and produced in limited quantity. e.g. Speciality solvents,
perfumes, medicines etc.
2. Chemical composition
a) Organic compound
Compounds having carbon atom in the main structure of the molecule is called organic
compound.
e.g. Hydrocarbons, phenols, carboxylic acid etc.
b) Inorganic compound
They are the compounds, which do not have carbon in the main structure. E.g. Na 2CO3, K2Cr2O7,
MgCl2.
c) Polymers
c) Polymers
They are the macromolecular mass compounds made from covalent bonding of repeating structured
units which may be natural, synthetic or semi synthetic. e.g. Polystyrene, polyvinylchloride etc.

3. Based on availability
a) Natural compounds
Compounds which are available in nature or produced or extracted from plant and animals are referred
as natural products. Due to large utilization and limited production the natural source is depleting. e.g. coal,
petroleum etc.
b) Synthetic products
Men made compounds are referred as synthetic products. They may be synthesized using natural
product or they are synthesized completely using other type of synthetic materials. Such product is suited to
direct applications.
e.g. Polystyrene, polyvinylchloride etc.
 4. Based on application
a) Catalyst
A substance, usually used in small amounts relative to the reactants, that either increases or decreases the
rate of a reaction without being consumed in the process. If consumed than it should regenerative at the end
of process. e.g. AlCl3, MnO2, Pt etc.
b) Bulk drug
Bulk drug is the active substance used in a drug formulation. It becomes an active ingredient of the
finished dosage form of the drug, but the term does not include intermediates used in the synthesis of such
substances. e.g. Pantoprazole, bisacodyl etc.
c) Resin
Resin is a natural or synthetic compound which begins in a highly viscous state and hardness with
treatment. e.g. Urea formaldehyde, epoxy, polyester etc.
d) Dyes and Pigments
A dye or a dyestuff is usually a coloured organic compound or mixture that may be used for imparting
colour to a substrate such as cloth, paper, plastic or leather in a reasonably permanent fashion.
Pigments are defined as colouring agents that are practically insoluble in the application medium,
whereas dyes are colouring agents that are soluble in the application medium.
e) Solvent
A liquid in which substances (or solutes) are dissolved to form a solution is called as solvent.
e.g. Benzene, THF, DMF, DMSO etc.

f) Miscellaneous
All other compounds which do not cover in above class are called as miscellaneous.
e.g. Fertilizer, glass etc.
ORIGINS AND DEVELOPMENT OF THE CHEMICAL PROCESS INDUSTRY
The development of the chemical industry can be divided into two periods.
The prescientific period which extended to the end of the eighteenth century was largely empirical, with
little under standing of the basic chemistry.
In the scientific period of the last 150 years the chemical industry has made phenomenal progress based
upon a sound knowledge of the principles underlying chemical processes.

Prescientific Chemical Industry.

The early prescientific chemical industry developed as any other trade or craft. Since those who practiced the
craft were not of the literate or learned class, none of the few remaining reports of early chemical processes
was written by people who were actually engaged in the craft. From the beginning of the sixteenth century,
more adequate records are available.
With no knowledge of chemical science and no means of chemical analysis, the early chemical craftsman
had to rely on previous art and on superstition. Progress was slow and confusion great. For example, in the
sixteenth century "oil of vitriol" was made from blue or green vitriol (now known as cupric or ferrous
sulfate). "Oil of sulfur" was made by burning sulfur. The latter was initially much more expensive than the
former, even though they were the same compound —sulfuric acid.

Probably the oldest chemical process industry is fermentation. Fermentation was known to the most
primitive man, possibly because of the ease of accidental discovery. Ale is the oldest fermented liquor, dating
ORIGINS AND DEVELOPMENT OF THE CHEMICAL PROCESS INDUSTRY
Prescientific Chemical Industry.

Probably the oldest chemical process industry is fermentation. Fermentation was known to the most
primitive man, possibly because of the ease of accidental discovery. Ale is the oldest fermented liquor, dating
to the Egyptians before 3000 b.c. Distillation began in the first century a.d., and by the thirteenth century
distillation of fermented liquors to concentrate alcohol was commonplace in Europe.

Recovery and use of metals began before 4000 b.c. The first metals found were gold and silver, since they
commonly occur in metallic form and are therefore easily recognized. The first metal to be extracted from its
ore was copper in Egypt and Mesopotamia about 3500 b.c. Other early metals include tin, lead, zinc, and
iron. Methods of smelting and of assaying were well developed by the sixteenth century. Early iron
production involved the heating of the oxide ore with charcoal to reduce it. Evidence of a forced draft or
blast has been found in ruins of Roman
furnaces.

Glass, cements, and ceramics were known in early times. The earliest cement was wet clay; Egyptians used
gypsum mortar; and the Greeks and Romans used lime mortar. Little basic improvement was made until the
discovery of portland cement in the nineteenth century. Ceramics began with baked-clay bricks and pottery
as early as 5000 B.c. Many early civilizations used glazed and colored ceramics. Porcelain was developed in
the eighth or ninth century in China.
ORIGINS AND DEVELOPMENT OF THE CHEMICAL PROCESS INDUSTRY
Prescientific Chemical Industry.

Vinegar (dilute acetic acid) was the earliest known acid since it was formed on the oxidation of fermented
liquors. No historical references are made to mineral acids until the fourteenth century. At this time nitric
acid was made from saltpeter (KNO3) and ferrous sulfate by heating the mixture and condensing the distilled
nitric acid.

The first industrial application of nitric acid was in the separation of gold from silver in the sixteenth century.
Industrial use of sulfuric acid developed later and became important only in the late eighteenth century, when
it was used to produce chlorine for bleaching cloth. Hydrochloric acid was discovered in the seventeenth
century. In the early nineteenth century the Leblanc process for making soda (Na 2CO3) also produced large
quantities of hydro chloric acid, and it became the cheapest and most widely used mineral acid of the period.

Early cleansing agents included many natural materials, such as the alkali found in wood ashes. True soap
was first mentioned in the first century. It was probably made by boiling ashes with a natural oil or fat. The
chemistry of soapmaking was not understood until the early nineteenth century.
ORIGINS AND DEVELOPMENT OF THE CHEMICAL PROCESS INDUSTRY
Scientific Chemical Industry.
Progress and growth of the early chemical industry were slow because there was little understanding of the
scientific principles underlying the various processes. The alchemists, who might have contributed to an
understanding of the processes, were preoccupied in attempting to convert base metals into gold and in
attempting to find the elixir of life. Alchemists were superstitious and mysterious, and often fraudulent and
deceitful.

In late eighteenth-century Europe, interest in the scientific principles of chemistry rapidly increased, and great
progress was made. Oxygen was discovered by the Swedish pharmacist Carl Wilhelm Scheele in 1770-1773
and independently by the English minister Joseph Priestley in 1774-1775. At the same time the great French
chemist Antoine Lavoisier clarified the role of oxygen in combustion, thereby refuting the popular phlogiston
theory. Lavoisier,s careful work in oxidation and other chemical fields did much to establish chemistry on a
sound quantitative basis. He recognized that organic compounds contained carbon and hydrogen, and he
developed methods for their determination. Between 1803 and 1808 John Dalton in England developed a
workable atomic theory which helped explain how elements combined into molecules, thereby making it
possible to consider chemical reactions on a quantitative basis.
ORIGINS AND DEVELOPMENT OF THE CHEMICAL PROCESS INDUSTRY
Scientific Chemical Industry.

The increased understanding of chemical science led to improvements and new developments in chemical
processing. The principal chemical industries in the early nineteenth century manufactured alkalies, acids, and
metals.
The organic-chemical industry began to develop after 1850. Although many natural products had been purified
for centuries, the lack of understanding of organic chemistry prevented the synthesis of organic compounds.
Cellulose was treated with nitric acid to produce nitrocellulose explosives. Rubber was introduced in the early
nineteenth century and was first vulcanized in the 1840s. Ether and chloroform were made on a small scale for
use as anesthetics. Synthetic organic chemistry may be considered to date from 1828 when Friederick Wohler
in Germany synthesized the natural organic product urea from inorganic ammonium cyanate. The work of
many great German chemists and of William Perkin in England led to the development of the aniline dye
industry, the
first large-scale synthetic organic chemical industry. The synthetic-drug industry developed in Germany after
1880. Attempts were made to synthesize a drug which would have action similar to the natural product quinine
in reducing fever. Although early attempts to synthesize quinine were unsuccessful, a similar-acting compound
kairine was synthesized by O. Fischer. Germany almost completely monopolized the synthetic drug and dye
industries until the First World War.
Figure 5: The top 10 chemical producing countries
inRef.
2010.
Chemical Industries Profile: Facts and Figures 2011, Cefic Chemdata
International
China dominates chemical sales globally

Page 24
 Chemical Engineering

Chemical engineering is a synthesis of chemistry and engineering. Although the profession grew
out of industrial chemistry, today it is based as much on physical principles as on chemical
fundamentals. There are many definitions of chemical engineering. Many of them are either too
specific or too vague. One popular definition: "A chemical engineer carries out on a large scale
reactions developed in the laboratory by the chemist," is true as far as it goes, but it does not show
the broad scope of problems encountered by the chemical engineer.

A facetious definition of chemical engineering makes a point: "A chemical engineer is one who talks
engineering in the presence of chemists, chemistry in the presence of engineers, and politics in the
presence of both."

Chemistry: the scientific study of the structure of substances, how they react when combined or in
contact with one another, and how they behave under different conditions.

Engineering: the activity of applying scientific knowledge to the design, building and
control of machines, roads, bridges, electrical equipment, etc.
 Chemical Engineering

Chemical engineering is a branch of engineering, dealing with processes in which materials undergo
changes in their physical or chemical state. The changes may concern size (for example in crushing or
milling of solid materials), energy content (as in heating, cooling, or evaporation), composition (as in
separations by, e.g. distillation, or membrane separations, as well as in chemical reactions) and/or other
application properties (e.g. flowability of powders and granulates, stability of emulsions).

The constitution of the American Institute of Chemical Engineers (A.I.Ch.E.) define chemical
engineering as- that branch of engineering which deals with the application of the principles of the
physical sciences, together with the principles of economics and human relations, to fields that pertain
directly to processes and process equipments in which matter is treated to effect a change in state,
energy content and composition. The definition is very broad, briefly, chemical engineering is the
development, design, and operation of various kinds of processes. Most chemical engineering activities,
in one way or another, are process oriented.

Chemistry: the scientific study of the structure of substances, how they react when combined or in
contact with one another, and how they behave under different conditions.

Engineering: the activity of applying scientific knowledge to the design, building and
control of machines, roads, bridges, electrical equipment, etc.
What are Chemical Engineers?
“Chemical engineers” use math, physical sciences (physics, chemistry), life sciences (biology,
microbiology and biochemistry), and economics to solve practical problems.

The difference between chemical engineers and other types of engineers is that they apply a
knowledge of chemistry in addition to other engineering disciplines. Chemical engineers may
be called “universal engineers” because their scientific and technical mastery is so extensive.
Jobs of a chemical engineer
A chemical engineer converts cheaper raw materials into finished products through processes
usually involving physical and/or chemical changes. A project is initiated by determining if there
is a market for a product, which may be a chemical, a processed food, a metal, a polymer or one
of the many other products produced by the process industries. For example, a chemist first
synthesizes a new drug in the laboratory, which after many tests is approved by the Food and
Drug Administration of the government. Then, chemical engineers develop and design the
process for producing the drug in large quantities. Chemical engineers are first and foremost
process engineers. That is, chemical engineers are responsible for the design and operation of
processes that produce a wide range of products from gasoline to plastics to composite materials
to synthetic fabrics to computer chips to corn chips.

The major areas of work within chemical engineering are given in the following list.
Process Research
Process development
Process design and evaluation
Plant design, construction, and operation
Production supervision
Marketing to sell product
 Chemical Technology

Chemical engineering is basically the study of chemical, their preparation and many more things
and chemical Technology is about using that chemical.
Engineering often focuses on theory and conceptual design, while technology programs
usually focus on application and implementation.
 Chemical Technology

Technology emerges from ideas and wills for creating and utilizing
the artifacts that fulfill human needs or desires. The outcome of
technology is just producing and employing objects, and it does not
depend upon thinking and using design equations, theories, etc.
Accordingly, skills and arts without specific knowledge are sufficient in creating and
managing the technology
Technology is more descriptive and empirical than engineering

Chemical technology is a branch of applied chemistry that concerns technical methods

and devices in order to manufacture a chemical product.

Chemical technologists and technicians are workers who provide technical support or services in
chemical-related fields. They may work under direct supervision or may work independently, depending
on their specific position and duties
 Chemical Technology

In general, it is usually not enough to create a technically successful product, and it must also meet
further requirements. For example, it is essential to introduce a new product that performs as well as
expected, does not cause unintended harm to the public at large, especially the environment, and
also achieves sustainability. Engineers take this responsibility to identify, understand and interpret
the constraints on a design in order to produce a successful result. They typically attempt to predict
how well their designs will perform to their specifications prior to full-scale production. In
developing technology, engineers carefully consider the constraints including available resources,
physical or technical limitations, flexibility for future modifications and some other factors, such as
cost, safety, marketability and serviceability.

Engineering is then defined as a creative application of scientific, economic, social and practical
principles to design, construct, operate, develop and maintain structures, machines, devices,
apparatus, systems, materials and/or manufacturing processes as required for an intended function,
economics of operation or safety to life and property. With full cognizance of the object or process,
engineers forecast the behavior of their designed equipment and/or plants under specific operating
conditions.

Engineering is more quantitative and less empirical than technology.

 Chemical Technology

The distinction between engineering and technology emanates primarily from differences in their
educational programs.
- Engineering curriculums are oriented toward development of conceptual skills and include a
sequence of fundamentals and courses built on a foundation of complex mathematics as well as
science courses.
Technology programs are geared toward applications and provide the students with only introductory
mathematics and science courses accompanied with a qualitative introduction to engineering
fundamentals.

- Graduates from engineering programs are called engineers,

while graduates of technology programs are called technologists.

- Clearly, engineering graduates’ career differs from those with technology background, technologist.
Engineering graduates are with a breadth and depth of knowledge that allows them to function as
conceptual designers and operators in product and process development.

- Once engineers enter the workforce, they typically spend their time planning, while technologists
spend their time making plans work
Chemical Engineering and Chemical Technology are closely related fields but differ in their focus and
application:
1.Focus:
1. Chemical Engineering: It primarily focuses on the design, operation, and optimization of
processes that involve chemical reactions and transformations. Chemical engineers often work
on large-scale industrial processes, such as manufacturing chemicals, fuels, or pharmaceuticals.
2. Chemical Technology: This field is more concerned with the practical application of chemical
processes and products. Chemical technologists work on implementing and maintaining
chemical processes in industries, ensuring they run efficiently and safely.
2.Education:
1. Chemical Engineering: Chemical engineers typically undergo extensive education in
mathematics, physics, chemistry, and engineering principles. They often work on the conceptual
and theoretical aspects of process design.
2. Chemical Technology: Chemical technologists typically receive more practical, hands-on
training in operating and troubleshooting chemical processes. Their education may focus less on
the theoretical aspects of engineering.
3.Roles:
1. Chemical Engineers: They may be involved in research and development, process design, and
management of chemical processes. They often work in industries like petrochemicals,
pharmaceuticals, and materials.
 the theoretical aspects of engineering.
3.Roles:
1. Chemical Engineers: They may be involved in research and development, process design, and
management of chemical processes. They often work in industries like petrochemicals,
pharmaceuticals, and materials.
2. Chemical Technologists: They are often responsible for day-to-day operations, quality control,
and process optimization in industries. They work closely with chemical engineers but have a
more operational and applied role.
4.Innovation vs. Implementation:
1. Chemical Engineering: It emphasizes innovation and the creation of new processes and
products. Engineers may be involved in developing new technologies and improving existing
ones.
2. Chemical Technology: It emphasizes the practical implementation of established processes.
Technologists ensure that existing processes are efficient, safe, and meet quality standards.
5.Scale:
1. Chemical Engineering: Often deals with large-scale industrial processes, including plant design
and construction.
2. Chemical Technology: Typically focuses on the operation and maintenance of existing plants or
processes.

In summary, chemical engineering is more theoretical and design-oriented, while chemical

technology is more practical and operation-focused. Both fields are essential for the chemical
industry, working together to develop, optimize, and maintain chemical processes and products.
Overview of Major Industries in Bangladesh

Ref.:Ahaduzzaman, Prottasha Sarkar, Aniqa Anjum and

Easir A Khan
Overview of Major Industries in Bangladesh Journal of
Chemical Engineering, IEB Vol. 30, No. 1 (2017) 51-58
 Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Bangladesh Chemical Industries Corporation (BCIC)
 Theoretical basis of chemical industry with special reference to industrialization of Bangladesh

Chemical/Process Industries in Bangladesh

(Public Sector)

BCIC: Bangladesh Chemical Industries Corporation

Fertilizer factories, Glass/ ceramics/ insulators/cement factories/Paper mills
BPC: Bangladesh Petroleum Corporation
Crude oil refinery
Petrobangla:
Gas well drilling, gas processing and distribution

(Private Sector)

Urea Fertilizer factory: KAFCO

Gas drilling and processing: Gazprom, Chevron, NIKO, ConocoPhillips, Santos
Glass and ceramics
Cement factories
Condensate refineries
Salt and sugar, Pulp and paper, Soap and detergents
Beauty products, Food processing, Gas transmission, Basic Chemicals, Pharmaceuticals
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh

Urea
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
Theoretical basis of chemical industry with special reference to industrialization of Bangladesh
 Future prospect of different types of Chemical industries in Bangladesh

Prospect and Challenges of Basic Chemicals Industries in Bangladesh

Textile Dyes and Auxiliaries in Bangladesh: Challenges and Prospects

BASIC CHEMICALS
Basic chemicals, also called commodity chemicals, tend to be produced in large volumes and have
little to no product differentiation among producers.
Basic chemicals are further classified into segments such as
inorganic chemicals,
bulk petrochemicals and intermediates,
plastic resins,
synthetic rubbers,
and manufactured fibers.

Basic chemicals are used in a wide range of industries and applications; they can be used to make
other chemicals and other manufactured goods or used to aid in processing. Pricing for basic
chemicals is highly correlated with the costs of raw materials, as well as capacity utilization,
which can result in low profit margins. In some cases, economic returns may be less than the cost
of capital.
Inorganic Chemicals
Inorganic chemicals are generally derived from metal and non-metallic minerals such as salts. Inorganic
chemicals serve both consumer and institutional markets including oil refining, chemical manufacturing, and
other manufacturing industries.
Chlorine and caustic soda (sodium hydroxide) are produced when salt, a simple compound formed from
sodium and chlorine, is broken down by electrolysis. Chlorine and caustic soda are used in a multitude of
industries and applications. For example, chlorine helps provide thousands of essential products, including
clean drinking water, energy-efficient building materials, electronics, pharmaceuticals, crop protection
compounds, and much more. Chlorine is also used in the manufacture of other chemical products and
intermediates, such as vinyls and propylene oxide. Caustic soda is used extensively in manufacturing processes
and in the production of soaps and detergents.
Industrial gases, also referred to as “air separation gases,” include oxygen, nitrogen, argon, hydrogen, and
carbon dioxide, among others. Major markets for industrial gases include steel and other metals production,
chemical manufacturing, petroleum refineries, and healthcare.
Inorganic dyes and pigments are used to impart color into other materials. Inorganic pigments tend to in
powder form and contain metals, such as cobalt blue and ultramarine violet. Inks are colored, liquid
dispersions of dyes (or pigments) that are suspended in a liquid (referred to as a vehicle) and used to impart
text and graphic designs onto plastics, paper, textiles, metals, and glass. Dyes and pigments are used in a
multitude of consumer and industrial applications. Note: not all dyes and pigments are inorganic.
Other examples of inorganic chemicals include acids (nitric, phosphoric, sulfuric, etc.), aluminum sulfate,
lime, soda ash (sodium carbonate), sodium bicarbonate, sodium chlorate, sodium sulfate, and sulfur, among
others.
Bulk Petrochemicals and Intermediates
Bulk petrochemicals (or primary petrochemicals) are simple molecules (or monomers) derived from hydrocarbon
feedstocks (and, thus, are considered organic chemicals). These basic building blocks are used as the starting
point for tens of thousands of other chemical products. Bulk petrochemicals include aromatics (which contain a
six-carbon ring structure), olefins (short “chain” molecules of two, three or four carbons in length), and methanol
(an alcohol). More than 90% of all organic chemistry is derived from seven petrochemicals: benzene, toluene,
and xylene (aromatics); ethylene, propylene, and butadiene (olefins); and methanol.
Bulk petrochemicals are combined with other chemicals to make into organic intermediates (or petrochemical
intermediates). Sometimes, multiple steps are required to produce an intermediate of the desired chemical
composition. Bulk petrochemicals and intermediates primarily serve other chemical manufacturers and
ultimately are used in industries including automotive, building and construction, consumer products,
electronics, and packaging. Bulk petrochemicals and intermediates are used in downstream derivatives such as
plastic resins, synthetic rubbers, manufactured fibers, surfactants, dyes and pigments, and inks.
Plastic resins are synthetic, long-chain compounds derived from one or more petrochemicals (ethylene, vinyl
chloride, styrene, propylene, etc.). They offer excellent molding, mechanical, chemical resistance, and other
properties. There are various types of plastic resins:
Thermosets are polymers that, in their final state as a finished product, cannot be resoftened by heat (and, thus,
cannot easily be recycled). Examples include epoxy, melamine, phenolic, polyester, polyurethane, and urea
resins. Major markets for thermosets include building and construction, furniture/furnishing, appliances,
transportation, electrical/electronic, ink, and coatings. End-use applications include adhesives and sealants,
electrical casting, surface coatings, building insulation, and automotive components.
Thermoplastics are polymers that are softened by heat and hardened by cooling in their final state as a
finished product. These resins can often be re-used and/or recycled. Emerging recycling and recovery
technologies often referred to as “advanced recycling” (or, “chemical recycling”), as well as traditional
mechanical recycling methods, allowing more types of used plastics to be recaptured and remanufactured
into new plastics and products. Examples of commodity thermoplastics include acrylonitrile butadiene
styrene (ABS), polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC).
Major markets for commodity thermoplastics include packaging, building and construction, consumer
products, automotive, and electronics. End-use applications include automotive trim and parts, appliance
parts, bags and film, medical equipment, bottles, and toys, among many others.
Engineering resins are thermoplastic polymers that have high-performance mechanical, thermal,
electrical, and chemical properties. Examples include acetal, fluoropolymer, polycarbonate,
polyphenylene sulfide, and other resins. These resins are often used to replace metal or glass in industrial
applications. They are also used to replace metals in applications such as valves, faucets, zippers, wire and
cable jacketing, non-stick coatings, microwave cookware, appliance and electronics housings, hair dryers,
bearings, gears, and myriad other products. Major markets for engineering plastics include automotive,
electrical/electronic, and consumer.
Synthetic rubbers are manufactured materials that exhibit a high degree of flexibility. Synthetic rubbers require
vulcanization, a process that cross-links the elastomer molecules. Examples include butyl rubber, ethylene-
propylene-diene monomer (EPDM) terpolymers, neoprene, nitrile rubber, styrene-butadiene rubber (SBR), and
thermoplastic elastomers. These materials are primarily used in the automotive sector and also used in the
construction and consumer product manufacturing industries. Major uses include tires, automotive bumpers
and fascias.
Manufactured fibers, also known as synthetic fibers, are synthetic cellulosic and polymeric textile fibers that
offer favorable, engineered attributes vis-à-vis natural fibers. Cellulosic fibers, such as acetate and rayon, are
made from raw materials from plants or trees (e.g., wood pulp). Meanwhile, polymeric fibers such as acrylic,
nylon, polyester, polyolefin, and others are derived from petrochemicals. Manufactured fibers are used in
apparel, home furnishing, automotive, construction and some industrial applications.
Other industrial chemicals include turpentine and other wood chemicals, carbon black and explosives, as well
as some other miscellaneous industrial chemical products. Key economic factors vary from segment to
segment but generally include increased consolidation, declining prices, environmental pressures, and
maturing demand.

Ref.: 2022 Guide to the Business of Chemistry

Page 50
Ref.: 2022 Guide to the Business of Chemistry
 Basic Chemicals Industries in Bangladesh

Basic Chemicals Industries in Bangladesh belong to mainly Chlor-Alkali Plant & its
Chlorinated product and Hydrogen peroxide plant. Main products are being produced from
these basic chemicals Industries are
Caustic Soda (NaOH),
Chlorine (Cl2),
Hydrochloric Acid (HCl),
Sodium Hypochlorite (NaOCl),
Stable Bleaching Powder (SBP),
Chlorinated Paraffin Wax (CPW) and
Hydrogen Peroxide (H2O2).

The Basic chemicals products of interest are now being supplied through import and local
production. We can name only four /five companies who produce basic chemicals locally.
ASM Chemical Industries Ltd., Global Heavy Chemicals Ltd, Samuda Chemical Complex
ltd., Tasnim Chemical Complex and HP Chemicals are very important names who took
challenges in this sector.
 Prospect and Challenges of Basic Chemicals Industries in Bangladesh

Basic Chemicals

Caustic Soda:
One of the main basic chemical is caustic soda. Its chemical name is Sodium Hydroxide (NaOH). It is an industrial
product. Different industries use Caustic Soda as raw material. Large consuming industries of Caustic Soda are Soap,
glass, drugs, paper & pulp, textiles, leather, sugar, water treatment plant (WTP) and effluent treatment plant (ETP) etc.
Hydrogen Peroxide:
Another main basic chemical is Hydrogen Peroxide (H 2O2). Market size in our country is ever bigger like caustic soda.
Textile, dyeing, medicine, pharmaceuticals, cleaning agent, pulp and paper etc. industries use hydrogen peroxide in huge
quantity.
Acetic Acid:
This acid is widely used in textile wet processing industry for neutralization of fabric. And also used to obtain acidic
condition in dyeing solution.
 Basic Chemicals

Hydrochloric Acid:
In the process of producing Caustic Soda, Hydrogen (H 2) and Chlorine (Cl2) are produced as bi-product. H2 and Cl2 can be
used to produce different bi-products such as Hydrochloric acid. It is used in textile industry, metal industry, effluent
treatment plant, pharmaceutical industries, leather industries and many other industries.
Stable Bleaching Powder (SBP):
It is a very useful chemical. Not only domestic customers use this chemical. It is used in textile industry, pulp and paper
industries and washing plant. Hospitals, WASA etc. organization use stable bleaching powder in bulk quantity. It has
domestic use for cleaning houses, toilets and other places.
Chlorinated Paraffin Wax (CPW):
This product is used to produce inflammable plastic. Plastic product does not produce flame rather it melts. This product
is used in PVC industries and in cable factories. Fire from electric short circuit is very common in our country. Production
of electric cable with CPW will help to reduce the risk of electric short circuit.

Without above these, sulfuric acid, different washing chemicals, sequestering agents, softening agents, different stabilizer
widely used in dyeing industry.
Production:
Demand 7.5
in 2022
Productio
in 2022
Productio
Demand 3
in 2022
Challenges of Basic Chemicals Industries and its product:
1. For Chlor-Alkali plant, more consumption of Cl2 is required to run the plant at design capacity.
PVC plant is required to consume excess Cl2 from Chlor-alkali Plant.
2. More water treatment plant to be made by WASA at the different area of the country to increase
liquid Cl2 consumption.
3. Cl2 can be used for de-coloring of dyeing waste colored water. In that case Liquid Cl 2
consumption from Chlor-Alkali Plant will be increased. The treatment of wastewater with
chlorine gas is a proven process and this was discarded primarily for high cost of chlorine gas.
The situation is different in Bangladesh and the cost of chlorine here favors the adoption of this
proven process.
4. FeCl3 and PAC (Poly Aluminium Chloride) industry to be made to increase liquid Chlorine
consumption.
5. Basic chemicals import should be stopped so that local production slow consumed chemicals like
HCl, SBP, CPW plant will be running well.
6. We have to make central ETP at different industrial area and HCl consumption should be increase
to balance Cl2 from Chlor-Alkali Plant.
7. Regeneration of resins of demineralized water plant to be done by HCl instead of H2SO4.
8. Now Basic Chemicals plants are suspending due to natural gas permission from the government
 Basic concept of process and process variables with their unit measurement
Process : A process is any operation or series of operations by which a particular objective is accomplished.
Those mentioned operations are involving a physical or chemical change in a substance or mixture of
substances.
The material that enters a process is referred to as the input or feed, and that which leaves is the output or
product. Therefore, several process variables are associated through input or output of a process stream.
The material entering a process: input, feed
The material leaving a process: output, product
If there are multiple steps, each will be a process unit with its own process streams

Fig. Process stream with various process variables

Table: Process variables
 Basic concept of process and process variables with their unit measurement
Process:
A process is a series of actions or steps taken in order to achieve a particular goal. In
engineering, a process can be considered as a series of mechanical or chemical operations
that change or preserve some equipment, devices, or systems.

- Process engineering focuses on the design, operation, control, optimization, and

intensification of chemical, physical, and biological processes.
Basic concept of process and process variables with their unit measurement
 THE SYSTEMATIC ANALYSIS OF CHEMICAL PROCESSES

Modern chemical processes are often extremely complex operations involving hundreds of pieces of
equipment. Without a systematic approach, it would be impossible to analyze an existing process or to design a
new process.

The typical chemical process is analyzed with five interdependent considerations:

1. Mass and energy balances
2. Thermodynamics and kinetics
3. Unit operations and chemical reactors
4. Instrumentation and control
5. Economics
These five subjects are closely dependent on each other, but their principles can be studied individually.

Mass and Energy Balances. The laws of conservation of mass and energy state that neither can be created or
destroyed, but that they may be changed in form. A mass balance is based on the conservation of mass : the
mass of materials leaving a process must equal the mass entering the process, if there is no accumulation of
mass within the process.
The law of conservation of energy requires that the energy added to a process must equal the energy removed
from the process plus any accumulation of energy within the process.
 THE SYSTEMATIC ANALYSIS OF CHEMICAL PROCESSES

Thermodynamics and Kinetics.

Thermodynamics deals with the transformation of energy from one form to another. Many important practical
conclusions can be derived from the two fundamental laws of thermodynamics. The first law of
thermodynamics states that energy cannot be created or destroyed, but it can be transferred from one form to
another. The second law states that in a process involving heat transfer alone energy may be transferred only
from a higher temperature to a lower one.
Thermodynamics also is useful in determining the composition of phases in equilibrium and in predicting the
distribution of chemical species in reaction equilibrium.

Kinetics considers the rate at which chemical compounds react. Data on rate of reaction are necessary in the
design of the industrial chemical reactors.
 THE SYSTEMATIC ANALYSIS OF CHEMICAL PROCESSES

Unit Operations and Chemical Reactors.

A chemical process can be broken down into a series of steps involving physical or chemical changes. The
chemical changes are chemical reactions and are carried out in various types of industrial chemical
reactors. Such reactors may be a small stirred pot or hundreds of feet of pipe. The quantitative calculation
of reactor size depends upon the rate of the reaction, the chemical equilibrium, the flow rates, and other
factors.

Fluid Mechanics:
In almost all chemical processes, some of the materials are fluid (gas or liquid), and they must be moved
through the process equipment. Energy to move the fluid must be supplied by a pump or other means.
Quantitative evaluation of the energy balance in flowing fluids requires a knowledge of the fundamental
thermodynamics and mechanics of fluids. Nearly all the other unit operations depend upon fluid
mechanics. Chemical engineers are sometimes referred to as "glorified plumbers," or "theoretical
plumbers.“
Of course, the chemical or mechanical engineer designs the piping system; the plumber installs it.
 THE SYSTEMATIC ANALYSIS OF CHEMICAL PROCESSES

Heat Transfer: Many chemical reactions progress more rapidly or go more to completion if the
temperature is other than room temperature. Furthermore, chemical reactions usually release or
absorb heat. Therefore, it is often necessary to heat or cool the reactants and products in an
industrial reaction. This makes heat transfer an extremely important unit operation.

Mass Transfer: In many unit operations one component of a fluid phase is transferred to another
phase because the component is more soluble in the latter phase. The distribution of components
between phases depends upon the equilibrium of the system. Such transfer of material between
phases is called mass transfer.
 THE SYSTEMATIC ANALYSIS OF CHEMICAL PROCESSES

Instrumentation and Control.

In all chemical processes it is necessary to know such process data as flow rates, compositions,
pressures, and temperatures, so that the operator and production engineer can tell that the process
is functioning properly. In the typical chemical process many instruments are used to measure,
indicate, and record the necessary process data.
It is often desirable to use an automatic control, so that not only does the instrument measure and
record a variable, but it also maintains the variable at a predetermined value.

Economics.
No matter how efficiently a process operates to produce a final product of high purity, the process is
a failure if the product cannot be sold at a profit. Before a chemical plant is built a thorough market
analysis is made to determine how much of the product can be sold and at what price. Present and
future competition from other producers must be carefully evaluated. As the plant is designed, many
economic analyses are made to determine the least expensive design which will produce the desired
quantity of product at a minimum price.
 Unit process and unit operation

A chemical process can be broken down into a series of steps involving physical or
chemical changes. The chemical changes are chemical reactions and are carried out in
various types of industrial chemical reactors. Such reactors may be a small stirred pot
or hundreds of feet of pipe.

Chemical process is combination of unit processes and unit operation.

The term unit operations has been restricted to those operations in which the changes are primarily
physical.
Unit processes involve chemical changes and imply commercialization of chemical reactions under
economically profitable conditions.
As for example, crystallization of sugar from a sugar solution is a unit operation, whereas the
production of ethanol from a sugar solution involves a unit process.

- Unit process involves principle of chemical conversions leading to synthesis of various useful product
and provide basic information regarding the reaction temperature and pressure, extent of chemical
conversions and yield of product of reaction, nature of reaction whether endothermic or exothermic,
type of catalyst used.
TABLE 1. PRINCIPAL UNIT PROCESSES AND UNIT OPERATIONS
Unit processes Unit operations
1. Combustion 1. Fluid dynamics
2. Oxidation 2. Heat transfer
3. Neutralization 3. Evaporation
4. Silicate formation 4. Humidification
5. Fermentation 5. Gas absorption
6. Electrolysis 6. Solvent extraction
7. Decomposition 7. Adsorption
8. Calcination, dehydration 8. Distillation and sublimation
9. Nitration 9. Drying, high-vacuum distillation
10. Esterification 10. Mixing
11. Reduction 11. Sedimentation
12. Ammonolysis fluidization
13. Halogenation 12. Filtration
14. Sulfonation 13. Screening
15. Hydrolysis, hydration 14. Crystallization vs. extraction
16. Hydrogenation, 15. Centrifugation
17. Alkylation 16. Size reduction
18. Condensation 17. Materials handling
19. Polymerization
20. Diazotization and coupling
 Process Flow diagram

A process flow diagram (PFD) is a diagram commonly used in chemical and process
engineering to indicate the general flow of plant processes and equipment. The PFD displays the
relationship between major equipment of a plant facility and does not show minor details such as
piping details and designations. Another commonly used term for a PFD is a flowsheet.

The abbreviation PFD (for Process Flow Diagram) is often used for process flow-sheets, The
flowsheet is the key document in process design. It shows the arrangement of the equipment
selected to carry out the process; the stream connections; stream flow-rates and compositions;
and the operating conditions. It is a diagrammatic model of the process.
 Process Flow diagram
Flow-sheet presentation
As the process flow-sheet is the definitive document on the process, the presentation must be clear,
comprehensive, accurate and complete. The various types of flow-sheet are discussed below.
Block diagrams
A block diagram is the simplest form of presentation. Each block can represent a single piece of equipment or a
complete stage in the process. They are useful for showing simple processes.
In the example each block represents the equipment for a complete reaction stage: the reactor, separators and
distillation columns.
Block diagrams are useful for representing a process in a simplified form in reports and textbooks, but have only a
limited use as engineering documents.
The blocks can be of any shape, but it is usually convenient to use a mixture of squares and circles, drawn with a
template.

Fig. The block diagram shows the

main steps in the balanced
process for the production of
vinyl chloride from ethylene.
Each block represents a reactor
and several other processing
 Process Flow diagram

Pictorial representation
On the detailed flow-sheets used for design and operation, the equipment is normally drawn in a
stylised pictorial form.
The symbols can be in British Standard, BS 1553
(1977), or
The American National Standards Institute (ANSI)

The symbols shown are in British Standard, BS 1553

 Process Flow diagram
Presentation of stream flow-rates
The data on the flow-rate of each individual component, on the total stream flow-
rate, and the percentage composition, can be shown on the flow-sheet in various
ways. The simplest method, suitable for simple processes with few equipment pieces,
is to tabulate the data in blocks alongside the process stream lines, as shown in
Figure 4.1.
 Process Flow diagram
A better method for the presentation of data
on flow-sheets is shown in Figure 4.2. In this
method each stream line is numbered and the
data tabulated at the bottom of the sheet.
 Process Flow diagram
A typical
commercial flow-
sheet is shown in
Figure 4.3.
Process Flow diagram
Process Flow diagram
Process Flow diagram
Symbol of some accessories

Figure. Flowsheet symbols for various operations

Symbol of some accessories