Chemical Engineering — 8th Semester Syllabus

Module 1: Unit 1.0 Introduction of Process Simulation (6 hrs.)

Introduction to process modelling and simulation • Introduction to process simulation software (e.g. Aspen Plus, CHEMCAD) • Steady state versus dynamic process simulation

Module 2: Unit 2.0 Simulation Software Interface (10 hrs.)

Introduction to basic simulation software interfaces • Steps involve in process simulation software • Building simple flowsheets • Component properties and thermodynamic models

Module 3: Unit 3.0 Data Input & Result Analysis (4 hrs.)

Data input for streams • Data input for unit operations (distillation, heat exchanger, pump, flash still, absorber, cyclone separator etc.) • Convergence of process • Result analysis • Tubular & graphical

Module 4: Unit 4.0 Simulation of Unit Operations (8 hrs.)

Introduction to distillation column simulation (simple binary systems) • Introduction to distillation column simulation (azeotropic systems) • Simulation of pumps and compressors • Simulation of mixing and splitting operations • Simulation of heat exchangers (basic models)

Module 5: Unit 5.0 Applications and Case Studies I (6 hrs.)

Simulation of basic chemical processes (e.g. simple separation processes, reaction systems) • Application of simulation to solve practical problems

Module 6: Unit 6.0 Applications and Case Studies II (6 hrs.)

Introduction to process optimization concepts (Sensitivity Analysis) • Case studies focusing on material and energy balance applications

Module 1: Unit- 1.0 Introduction to Process Engineering (7 hrs.)

Introduction • Alternative routes in process engineering • Approach to chemical plant design • Preparation of manuals • Test runs • Troubleshooting • Cost cutting • Data sheet • Green engineering and process intensification

Module 2: Unit- 2.0 Process Design of Piping and Moving Devices (7 hrs.)

Introduction • Process design of piping • Process design of pumps with performance of pumps • Troubleshooting of fluid flow systems

Module 3: Unit-3.0 Process Design of Heat Exchangers I (7 hrs.)

Introduction • Shell and tube heat exchanger • Design of parts of exchanger • General design method of exchanger • Method to calculate heat transfer and pressure drop calculations

Module 4: Unit- 4.0 Process Design of Heat Exchangers II (7 hrs.)

Delaware method for design of baffled exchanger • Heat Exchanger Networking (HEN) and Heat Integration

Module 5: Unit- 5.0 Process Design of Tall Columns (7 hrs.)

Introduction • Criteria for Selection • Distillation Column Design • Batch distillation and with rectification • Multicomponent batch rectification • Energy conservation in distillation • Criteria for selection and Design of packed tower absorber

Module 6: Unit- 6.0 Process Design of Utility Systems (7 hrs.)

Introduction • Design of Process Heating Systems • Design of Process Cooling Systems • Compressed Air Systems • Inert Gas Systems

Module 1: Unit-1.0 Sustainable and Green Chemical Processing (7 hrs.)

Sustainability: Concept, Overview and attributes of sustainability • Green Chemistry and 12 Principles of Green Chemistry • Case studies to demonstrate the concept of atom economy and E-Factor • Numericals based on estimation of atom economy and E-factor • Integration of Ecofriendly Practices: Green approach in raw material processing • Alternate pathway case studies (Ibuprofen and Propylene oxide synthesis) • Shift from Chemical transformation to biochemical transformation (Biodiesel and acrylamide manufacturing)

Module 2: Unit-2.0 Circular Economy and Waste Minimization (6 hrs.)

Linear Economy • Circular Economy and Industrial Ecology • 5R approach for waste minimization relevant examples • Waste to resource conversion: Waste valorization (Flowsheet and Process description) • Pyrolysis of tyres and plastics • 2G ethanol manufacturing from waste biomass • Zero Liquid discharge: Concept, component and process flow

Module 3: Unit-3.0 Chemical Process Intensification and Advanced Separation (6 hrs.)

Process intensification Concept and approach of intensification • Microreactors and Membrane reactor: Constructional features and applications • Microwave, Cavitation and Photochemical based intensification: Features and applications • Advanced separation processes: Reactive distillation, Supercritical fluid extraction and pervaporation • Heat Integration Network and its application in Energy optimization

Module 4: Unit-4.0 Nanotechnology and Advanced Material (10 hrs.)

Nanotechnology: Introduction and its significance in chemical engineering • Physical, chemical, Electrical and optical properties of nanomaterials • Classification examples and applications of nanomaterials on the basis of: Dimensions: Zero, one, two and three dimensional • Origin: Natural and engineered • Pore size: Microporous, mesoporous and macroporous • Composition: Carbon based, inorganic, organic and composites • Introduction and features of Advanced materials such as Metal Organic Framework (MOF) • Smart and Surface responsive materials • Application of above materials in: Catalysis, Energy and hydrogen storage, Drug delivery, Carbon capture, As a sensor that responds to changes in pH. temperature or chemical nature

Module 5: Unit-5.0 Digital Chemical Engineering - Industry applications (8 hrs.)

Journey from Industry 1.0 to 4.0 • Digital Twins: Concept, components like physical assets (reactors, distillation columns, process vessels, etc.), IIoT sensors, visual model and data link • Component Digital twin like IIoT Sensors Data logger, real time data integration and analysis tools • Data driven Physics based Simulation model that represent process/equipment • Controllers and visualization dashboard equipped with AR

Module 6: Unit-6.0 Digital Chemical Engineering AI applications (5 hrs.)

Al applications in Chemical Engineering • Process Optimization • Reaction Prediction • Process Fault Detection • Quality Control • Process Simulation and Modeling • Energy Optimization

Module 1: Unit 1.0 Petroleum-An Overview (6 hrs.)

Petroleum reserves in India • Methods of petroleum exploration • Drilling of petroleum • Physical properties of petroleum • Constituents of crude oil • Petroleum recovery techniques • Petroleum refineries in India • Global crude oil producer countries

Module 2: Unit 2.0 Refining of Petroleum I (10 hrs.)

Dehydration and desaltification of petroleum • Atmospheric and vacuum distillation unit • Petroleum fractions with their boiling range, carbon number and uses • Properties of petroleum fractions with definition and significance: API gravity, viscosity, flash point, fire point, aniline point, smoke point, pour point, cloud point, octane number, cetane number, diesel index, drop melting point of wax, calorific value, carbon residue and penetration index

Module 3: Unit 3.0 Refining of Petroleum II (5 hrs.)

Characterization of Petroleum Fractions: redwood viscometer, flash and fire point apparatus (Pensky-martens apparatus, Abel's apparatus, Cleveland open cup), cloud point apparatus, pour point apparatus, drop melting point apparatus, smoke point apparatus, aniline point apparatus and Conradson carbon residue apparatus

Module 4: Unit 4.0 Petroleum Refinery Processes (7 hrs.)

Thermal Cracking: vis breaking process, steam cracking process and delayed coking • Catalytic Cracking: fluid catalytic cracking • Alkylation: Sulphuric acid process, Hydrogen Fluoride Process • Hydrocracking Process • Catalytic Reforming Process • Isomerization Process • Polymerization Process • Catalytic Hydrotreating Process

Module 5: Unit 5.0 Chemicals Derived from C1 to C4 Chemicals (8 hrs.)

Petrochemical from C1 chemicals: (a) Methanol (b) Formaldehyde c) Chloromethane • Petrochemical from C2 chemicals: (a) Ethanol from chemical synthesis route (Hydration of ethylene), (b) Ethylene oxide, (c) Vinyl chloride • Petrochemical from C3 chemicals: (a) Acetaldehyde (b) Isopropanol (c) Propylene oxide • Petrochemical from C4 chemicals: (a) Butadiene (b) Methyl tertiary butyl ether, (c) Butyl acetate

Module 6: Unit 6.0 Aromatics (6 hrs.)

Separation of aromatic hydrocarbon (BTX) from reformate by using Udex process • Aniline manufacturing process from hydrogenation of nitrobenzene • Benzoic acid manufacturing process from toluene

Module 1: Unit-1.0 Solid Waste & Management (7 hrs.)

Introduction to solid waste • Types, properties & sources of solid waste • Solid waste generation, collection of solid waste • Reduce-Reuse-Recycle (RRR) approach for solid waste • Mass balance for biological conversion (composting/bio methanation) • Recovery of biological & thermal conversion products • Design, site selection & operation of sanitary landfills • Key aspects of landfill design • Characterization, transportation & disposal of hazardous waste • E-waste Management

Module 2: Unit-2.0 Treatment of Liquid Waste (7 hrs.)

Introduction to liquid waste • Parameter of liquid waste • Treatment methods for liquid waste • Primary Methods: screening and sedimentation • Secondary Methods: activated sludge process and trickling filter • Tertiary Methods: nutrient removal and disinfection

Module 3: Unit- 3.0 Regulations for Waste Management (7 hrs.)

Introduction to acts for waste management in India • Bio medical waste rules 1998 • The hazardous waste rules 2008 • The plastic waste rules 2011 • The E-waste rules 2011 • Solid waste management rules 2016 • Penalties for non-compliance

Module 4: Unit-4.0 Treatment of Hazardous Waste (7 hrs.)

Introduction to hazardous waste • Hazardous Waste: collection & storage • Rules & Regulations for storage & handling • Treatment technologies for waste: physical & chemical • Management of biomedical waste & nuclear waste

Module 5: Unit- 5.0 Energy From Waste I (7 hrs.)

Introduction: Concept of energy from waste • Energy production technologies: Incineration, Gasification & pyrolysis

Module 6: Unit-6.0 Energy From Waste II (7 hrs.)

Heat Recovery System: regenerator, heat pipe exchanger