This is actually a vast question! So let me elaborate my
views about the chemical engineering profession through a story. This tale is quite long but I hope you will find it informative and interesting. X is a chemical engineer. A chemical engineer par excellence. One fine day, he is summoned by his boss and given a new assignment. The chemists of the company have found that if reactants A and B are mixed, then the valuable product P will be formed. X's boss tells him to engineer this reaction into being. And so X sets to work. 1. Thermodynamics and Kinetics: Being a healthy sceptic, X is not entirely convinced about the chemists' calculations. So he first studies the thermodynamics of the process to understand the conditions at which it would be feasible to carry out the reaction. Temperature, pressure, composition, s olvent nature ... all is variables which X can adapt and fine-tune to the process at hand. He also understands the factors that affect the reaction rate to use them favourably. Apart
from the reaction being feasible and fast, he also
has to worry about side reactions, stability of all concerned species and phase homogeneity. These are complex calculations and so he uses computational techniques and softwares to help him in making decisions. He also requests the chemists to double-check his results in some lab experiments. 2. Targets and Material Balances: Once X is satisfied that the reaction can be implemented, he establishes targets and goals. The scope and ambition of the process is decided at this step. He identifies the sources of A and B - nearer the better. If they're very far, he wonders if he can make them himself. A few calculations give him an estimate as to how much P will need to be produced for economically viable operation, and he deduces the quantities of A and B from that as well. To help explain the concept of material balances, X always likes to show the following diagram: 3. Reactor Design: Now X turns to the heart of the process, the reactor. He has briefly looked at possible catalysts when studying the kinetics, but this time he goes deeper. He plays around with some molecular simulation tools to find what catalyst could give the best results in terms of conversion, yield and selectivity. He also
factors in the catalyst stability into his
calculations. Once he's done on this front, he wonders what reactor design to use. A fixed bed? A fluidized bed? A stirred tank? A membrane reactor? Is it advantageous to use multiple reactors? How large should these reactors be? Of what material should they be made? He pays special attention to the physical phases and chemical natures of the participating species while making this decision. When asked, he shows some schematic reactor designs labelled with typical chemical engineering abbreviations: 4. Equipment Design: X realizes early on that just the reactor isn't sufficient. Unfortunately, A and B are not obtained in very pure form and so he must do some 'preprocessing'. He considers a variety of techniques such as washing with a solvent, selective chemical reactions, filtration, crystallization, distillation ... and chooses the one that is the most suitable. These processes need special equipment and he designs them accordingly. There's also some 'post processing' he has to accomplish, for P is not the sole product obtained. So depending on the exact requirements, he installs equipment like absorbers, adsorbers or liquefies. To
simplify his task, he uses a computer which
returns him the design once he specifies the layout. His distillation towers and gas absorption scrubbers often look like what are shown here: 5. Energy Balances: "Nothing comes for free" this is one of X's favourite lines. For effective operation, he needs to supply energy to specific equipment and take away energy from others. He also learns that the reaction of interest is exothermic and thus wants to make sure there is no chance of hotspots forming in the reactor. He has to decide whether he prefers fluidcarrying coils or jackets or resistive heating or chemical heat carriers ... and also how to ensure efficient heat transfer between these devices and the equipment. Exchanging heat between multiple streams is one of X's best bets and so he develops a heat exchanger network. He also has to consider declining efficiency with time due to effects like fouling or wearing out of mechanical parts. Due to the large number of variables and calculations, X relies on some special computational tools, some aspects of which he has tweaked and improved. His heat exchanger networks are usually somewhat as shown below, full of small symbols and fine print.
6. Piping and Instrumentation: To avoid high
levels of unconsumed reactants, X considers the possibility of having a recycle stream for multiple runs. A purge stream might also be needed to avoid accumulation of inert substances and impurities. He also explores methods to transport the reaction mixture from one equipment unit to another. This could be achieved by gravity or using pumps or perhaps even conveyor belts. He designs these as well and optimizes the connecting pipes on the basis of pressure drop and space considerations. He also sets up measuring devices to monitor important parameters like the temperature, pressure, flow rate and composition during operation, most of which he has designed himself too. These are all compiled into a piping and instrumentation diagram(P&ID), and X is always immensely proud of these! Look at him showing off one of his diagrams: 7. Control and Automation: It's important to ensure that the system conditions stay within certain limits for stable operation. This is why X implements a large number of sensors and actuators which enable him to control the process. He has a large number of options here as well, with different types and
mechanisms of controllers (PID, Adaptive,
Fuzzy logic etc.) as well as a variety of valves with different configurations. Also, X decides how much of this control should be automated and how much of it should be manually operated. During this process, he keeps in mind his motto, "Safety first", for it's better to be safe than sorry every time. Here's one of X's photographs of a refinery control room that he'd worked in: 8. Environmental Concerns: X is an environmentally-sensitive engineer. And so he makes sure that no potentially harmful substances are released into the environment. This requires special units or isolation measures - he could employ methods like chemical treatment, electrostatic precipitation, combustion-dispersal or controlled dumping. If possible, he also tries to find a use within his own industry for any toxic products that are produced. Here are some images he shows to pictorially describe some measures undertaken: 9. Alternative Energy Sources: X's boss often tells him they will soon run out of oil. X doesn't believe him because he is aware of the untapped
reserves of heavy oils but agrees that they pose a
threat to the environment. Hence, he too is often on the lookout for alternative sources of energy that can be used to run his operations. Being in a closed environment, he can't directly take advantage of renewable sources like wind and water, but the prospect of biofuels excites him for they could originate from natural sources like sugarcane. He's trying to adapt his systems to run using fuel cells which could be of different types (PEM, methanol, solid-state, etc.) and often looks at figures like the one below to digest their variety and versatility: 10. Bioengineering Approaches: One of X's biologist colleagues has also succeeded in making him enthusiastic about the potential of bioengineering. He now knows about mutations and plasmids as well as the advantages of using enzymes to carry out reactions. Metabolic engineering is a new coinage wherein he's learnt that one can change the properties of organisms like bacteria to attain desirable functionalities. The growing use of computational models for cellular networks and advancement in wet lab technologies has meant that X also considers bioreactors whenever he is given a task. This is why it's not uncommon to
see X poring over such cellular networks to
understand biological processes better:
11. New Materials: Another of X's colleagues
has enlightened him about new materials. He has to come to learn of new membranes that can filter better and improved materials that increase adsorption efficiency. Polymers have found their way into his dictionary and he is learning to take advantage of their different properties. Bioinspired materials are also growing in prominence by adapting the systems already in existence in Nature and X keenly reads the latest research on these, a schematic of which is shown below: 12. Nanotechnology: X has also been alerted to the advantages of using very fine particles for industrial applications. Nano emulsions and nanoparticle catalysts are hot areas in the modern day. These particles also have the ability to act as supports or carriers for other chemicals as well as dispersing agents. He carries out many simulations on these systems using diverse types of nano systems, some of which are shown here:
13. Scale Down: Before investing heavily in a
plant, X ponders about making aprototype to test his analysis. He reduces the size by conserving certaindimensionless groups across scales - the choice of this dimensionless no. is different for different equipment and constitutes an important decision. Here are some basic dimensionless numbers that X uses very often: 14. Microfluidics: Having taken a cue from some of his chemist friends, X is now thinking of microfluidic reactors. Using small tubes in a controlled fashion can be advantageous in many ways, especially for testing purposes. The dynamics in such systems might also be very different from that at the larger scales, so he is actively studying the phenomenon observed in microchannels and chips like the one shown here. 15. Startup: One of the most important and tense times for X is 'startup day'. Much of his analysis has been for situations when things are at steady state and he's had to rely on correlations and simplifications to model and analyze the events occurring during startup. He ensures the feed is properly preconditioned, the equipment are functioning properly, the
sensors are working and the controls are
responding before switching on the operation. During this day, he monitors all readings carefully and takes appropriate action, often manually, to ensure things progress smoothly in the run up to steady state. 16. Packaging and Delivery: Now the product P is being steadily obtained but it needs to be converted to the appropriate form and delivered. Perhaps it needs to be made into tablets, perhaps it needs to be packaged as a powder, perhaps it needs to becompressed as a gas. X calls the shots and ensures proper formulation,handling and delivery. He also expresses his sentiments about the product appeal and target group to the designers and promoters, and this picture is one of his prized exhibits. 17. Operation and Troubleshooting: A year after startup, the quality of product Phas degraded. X is worried that one of the equipment units is malfunctioning and runs some detection tests - the product batches obtained during this time have to be discarded. He does not want to shut down the plant and attempts to make somemodifications to the existing conditions to improve performance. In the meantime, he tries to identify and isolate the
faulty point to take necessary corrective action,
often taking the help of fault trees, event trees, or the like. 18. Redesign: After a few more years, the source of A has run out and a new source is found and tapped. But X finds that the quality and nature of this new feed material is different from that of the earlier case. Unfortunately, it is too expensive to dismantle the entire operation and customize it anew so he must adapt to these new conditions as best as he can. This might need a change in operating conditions, or even an add-on unit, and X has to make an appropriate decision. Another year later, the government issues a notice increasing the minimum concentration of P in the product. Some more changes and redesigning is therefore necessitated to continue to conform to norms without raising the price excessively. To illustrate his point, X often shows this picture to illustrate the different crude oil grades and the resulting difference in properties: 19. Decommission: Many years have passed and the process and system in place are now too old. The system in place has to be dismantled and it is old man X who is still in charge. He decides which components can
be re-used, which can be modified and
adapted and which has to be sent away as scrap. He chalks out a disposal plan and ensures that all the raw material is consumed before dismantling. The size and scale of this process can be imagined when one looks at some of the mammoth plants that X has setup and run, one picture of which is shown here. 20. Reporting and Documentation: Through all of this, X maintains an extensive and exhaustive set of documents for both internal and external use. Periodic presentations and discussions enable him to improve the design and efficiency of the processes that he is tasked to 'engineer into reality'.
Moral of the Story: Chemical engineering is a
diverse field which transcends boundaries by incorporating elements from many disciplines. A chemical engineer could be devising or characterizing catalysts, designing new and more efficient plant equipment, improving control strategies, formulating new fuels and energy sources, engineering biological systems, innovating novel materials, going meso or nano,
ameliorating packaging and transport, and much
more. A chemical engineer could also be attacking fundamental questions in fluid hydrodynamics, solid flows,chemical interaction modelling, plant startup and shutdown, polymer theory,biosystem analysis, and many other areas all of which have numerous unsolved mysteries. Hope you found this story interesting and enjoyable
(Simulation Foundations, Methods and Applications) Ercan M. Dede, Jaewook Lee, Tsuyoshi Nomura (Auth.)-Multiphysics Simulation_ Electromechanical System Applications and Optimization-Springer-Verlag L