2.2. Step 1-Batch Versus Continuous Process

discussed in some detail, and the general philosophy about the decision-making process will be
covered. However, because Steps 4 and 5 require extensive discussion, these will be covered in
separate chapters (Chapter 12 for separations, and Chapter 15 for energy recovery).
2.2. Step 1—Batch Versus Continuous Process
It should be pointed out that there is a difference between a batch process and a batch (unit)
operation. Indeed, there are very few, if any, processes that use only continuous operations. For
example, most chemical processes described as continuous receive their raw material feeds and ship
their products to and from the plant in rail cars, tanker trucks, or barges. The unloading and loading of
these materials are done in a batch manner. Indeed, the demarcation between continuous and batch
processes is further complicated by situations when plants operate continuously but feed or receive
material from other process units within the plant that operate in a batch mode. Such processes are
often referred to as semi-batch. A batch process is one in which a finite quantity (batch) of product is
made during a period of a few hours or days. The batch process most often consists of metering
feed(s) into a vessel followed by a series of unit operations (mixing, heating, reaction, distillation,
etc.) taking place at discrete scheduled intervals. This is then followed by the removal and storage of
the products, by-products, and waste streams. The equipment is then cleaned and made ready for the
next process. Production of up to 100 different products from the same facility has been reported [3].
This type of operation is in contrast to continuous processes, in which feed is sent continuously to a
series of equipment, with each piece usually performing a single unit operation. Products, by-
products, and waste streams leave the process continuously and are sent to storage or for further
processing.
There are a number of considerations to weigh when deciding between batch and continuous
processes, and some of the more important of these are listed in Table 2.1. As this table indicates,
there are many things to consider when making the decision regarding batch versus continuous
operation. Probably the most important of these are size and flexibility. If it is desired to produce
relatively small quantities, less than 500 tonne/y [1], of a variety of different products using a variety
of different feed materials, then batch processing is probably the correct choice. For large quantities,
greater than 5000 tonne/y of product [1], using a single or only a few raw materials, then a continuous
process is probably the best choice. There are many trade-offs between the two types of processes.
However, like most things, it boils down to cost. For a batch process compared to the equivalent
continuous process, the capital investment is usually much lower because the same equipment can be
used for multiple unit operations and can be reconfigured easily for a wide variety of feeds and
products. On the other hand, operating labor costs and utility costs tend to be much higher. Recent
developments in batch processing have led to the concept of the “pipeless batch process” [4]. In this
type of operation, equipment is automatically moved to different workstations at which different
processes are performed. For example, a reactor may be filled with raw materials and mixed at
station 1, moved to station 2 for heating and reaction, to station 3 for product separation, and finally
to station 4 for product removal. The workstations contain a variety of equipment to perform functions
such as mixing, weighing, heating/cooling, filtration, and so on. This modular approach to the
sequencing of batch operations greatly improves productivity and eases the scheduling of different
events in the overall process.
Table 2.1. Some Factors to Consider When Deciding between Batch and Continuous Processes
Finally, it is important to recognize the role of pilot plants in the development of processes. It has
been long understood that what works well in the laboratory often does not work as well on the large
scale. Of course, much of the important preliminary work associated with catalyst development and
phase equilibrium is most efficiently and inexpensively completed in the laboratory. However,
problems associated with trace quantities of unwanted side products, difficult material handling
problems, and multiple reaction steps are not easily scaled up from laboratory-scale experiments. In
such cases, specific unit operations or the entire process may be “piloted” to gain better insight into
the proposed full-scale operation. Often, this pilot plant work is carried out in batch equipment in
order to reduce the inventory of raw materials. Sometimes, the pilot plant serves the dual purpose of
testing the process at an intermediate scale and producing enough material for customers and other
interested parties to test. The role and importance of pilot plants are covered in detail by Lowenstein
[5].
2.3. Step 2—The Input/Output Structure of the Process
Although all processes are different, there are common features of each. The purpose of this section is
to investigate the input/output structure of the process. The inputs represent feed streams and the
outputs are product streams, which may be desired or waste streams.
2.3.1. Process Concept Diagram
The first step in evaluating a process route is to construct a process concept diagram. Such a diagram
uses the stoichiometry of the main reaction pathway to identify the feed and product chemicals. The
first step to construct such a diagram is to identify the chemical reaction or reactions taking place
within the process. The balanced chemical reaction(s) form the basis for the overall process concept
diagram. Figure 2.1 shows this diagram for the toluene hydrodealkylation process discussed in
Chapter 1. It should be noted that only chemicals taking place in the reaction are identified on this
diagram. The steps used to create this diagram are as follows:

2.2. Step 1-Batch Versus Continuous Process

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discussed in some detail, and the general philosophy about the decision-making process will be

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