Fundamentals of Chemical Technology and Chemicals Management 1200-2EN-FCHTER

The goal of the course is to provide basic information on the most important chemical and physical laws and chemical engineering principles in chemical technology and relevant technical processes. Students should know terminology associated with applied chemistry and technology. Applications will be in areas such as mass and energy transfer, catalysis, separation techniques including separation on membranes, filtration, reversible osmosis, drying and waste water treatment. The design of a project from conception to implementation including preliminary feasibility study, preparation of process flow diagram, process design, equipment sizing (design), and a technical-economic analysis of project will be treated. Estimation and calculation of investment costs.
Sustainable development and chemicals management. Chemical, power, and food processing industry – common features and differences. Principles and concepts of Green Chemistry. Characteristics of clean technology. Renewable and non- renewable resources. Biotechnological processes – examples. Large-scale chemical processes – resources and products (full-scale manufacturing, properties and applications of fuels, polymers, ceramic materials and metals).
Safe handling of chemical materials. Safety rules and risk assessment in chemical industry.
Valuation and commercialization of intellectual property such as innovations and academic research outcomes. Design of chemical technology process and evaluation of its costs, safety and risk assessment in manufacturing processes. Introduction to economics of chemical product engineering process (competitiveness of manufacturing processes - BAT (Best Available Techniques), equipment design and performance specifications, factors to be considered for selecting the plant site, overheads in chemical plants)
Topics of the lecture:

1. Chemical technology relations to fundamental sciences.
2. Terminology associated with applied chemistry and technology (for example: reactor, stationary state, continuous and batch processes, contacts, heat exchanger, fluid phase etc).
3. Chemical and physical laws employed in material and energy balances preparation.
4. Technological process development.
4.1. Chemical and technological concept of a technological process.
4.2. Equipment sizing.
4.3. Technological principles.
5. Parameters determining efficiency of a full scale manufacturing process.
5.1. Parameters connecting to resources.
5.2. Parameters connecting to products.
5.3. Other parameters.
6. Elementary processes and units.
7. Mass transfer.
7.1. Terminology associated with material balance.
7.2. Basic rules: Fick’s law.
7.3. Reactor types used in batch and continuous processes.
8. Energy transfer.
8.1. Types of heat exchanger.
9. Separation techniques.
9.1. Physicochemical principles of rectification, extraction, filtration, osmosis, reversible osmosis, drying.
9.2. Waste water treatment.
10. Chemical, power and food processing industry – general characteristic, common features and differences.
11. Biotechnological processes – general description.
11.1. Examples
11.1.1. Beer manufacturing.
11.1.2. Synthetic ethanol manufacturing.
11.1.3. Milk products manufacturing.
12. Large-scale chemical processes.
12.1. Fuels manufacturing (main resources and products properties, applications).
12.2. Polymers manufacturing (synthesis, resources and products properties, applications).
12.3. Ceramic materials manufacturing (technologies, characteristics).
12.4. Metals – exemplary technologies (resources, products properties and applications).
13. Safe handling of chemical materials
13.1. Characterization of materials and their critical physical and chemical properties.
13.2. Software application (OECD QSAR) for assessing the hazards of chemicals.
14. Regulation (EC) No 1907/2006 of the European Parliament and of the Council on the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH)
14.1. Aim, scope and application this Regulation
15. Safety rules and risk assessment in chemical industry
15.1. Location of plant
15.2. Chemical risk assessment (compatibility, storage, fire protection, toxity, hazard index rating, fire and explosion hazards)
15.3. Process safety assessment (HAZOP, assessment of process equipment, scrubbing systems, management of change procedures, etc)
15.4. Electrical safety (hazardous area, protection against static electricity, specialized flameproof equipment)
15.5. Safety audits
15.6. Emergency planning
15.7. Safety and Health training (introductory and regular training)
15.8. Risk management and insurance planning
16. Valuation and commercialization of intellectual property
16.1. Defining intellectual property
16.2. Methods of valuation
16.3. Late twentieth century inventions-examples
17. Design of chemical technology process and evaluation of its costs
17.1. Factors influencing plant location
17.1.1. Raw material sources
17.1.2. The supply and cost of labor
17.1.3. Fuel and Power
17.1.4. Water
17.1.5. Transportation facilities
17.1.6. Markets
17.1.7. Climate
17.1.8. Competition
17.2. Competitiveness of manufacturing processes - BAT (Best Available Techniques)
17.3. Equipment design and performance specifications
17.4. Cost components
17.4.1. Fixed costs
17.4.2. Variable costs
17.5. Overheads in chemical plants
17.5.1. Fixed costs of production
17.5.2. General plant overhead components
17.5.3. Salary overhead