Introduction to Chemical Product

Design
(ENCH600023, ENBP600014: 4 SKS)
Capstone Course

PREPARING FOR ENGINEERING

PRACTICE
Knowledge

Skills
2014

Instructors
Prof. Widodo W. Purwanto (WD)
Dr.rar.nat. Yuswan Muharam (YM)
Prof. Dr. Misri Gozan (MG)
Dewi Tristantini PhD (DT)
Assistants:

Muthia (Koordinator)
Haisa Yuara
Laras Novitasari
Sesilia Genesy
M. Ilham Chairat
Olivia Cesaran

Course Outcomes
Mahasiswa mampu menggunakan
pengetahuan yang didapat dari beberapa
mata ajaran sebelumnya pada disain produk
kimia secara lengkap yang meliputi: Needs,
Ideas, Selection, Manufacture, Supply Chain,
HSE, dan Economics.
Mahasiswa memiliki kemampuan
pemecahan masalah dan bekerja dalam tim.
Mahasiswa memiliki kecakapan sebagai
wirausaha.

Course Content
Syllabus and Design Topics
Chemical Industry Trend
Chemical Engineering
DesignTrends
Chemical Product Design

Chemical Industry Trend

Major development of ChE

Expanding the scope in ChE

The Promise of Chemical

Industry -Multiple Scales
Three Scales of Knowledge Application
Holistic /Tera Scale
Perspective

Scales of Engagement

Large Scale Systems Dynamics

Issues
s
Global Ecological Balance ? line
ip
Energy Balance ?
c
s
Social Structures ?
di
le
p
i
t
ul
M
of
ss
e
oc
r
P
n
Raw materials tio
a
iz
l
ia
c
So
Cellular /Nano
Level
functionalities

Microscopic
Perspective
2008 Partha S Ghosh

Tera Scale

Current
Scale
1. Efficiency
2. Conservation
3. Recycling

Micro Nano
Scale

Role of ChE

From Bulk to Molecular

Processing

Raw Materials to Consumer

Products

Chemical Product Types

Scope of
Chemical Product and Process
Industry

Design of chemical
products begins
with the
identification and
creation of
potential
opportunities to
satisfy
societal needs and
to generate profit

Process operation for

3 types of chemical products

Chemical Product
Tree
Performance

Purity
/composition

Source: Gani, 2004

Chemical engineers
&products

Trend affecting new product

strategies in the chemical
industry

Chemical Commodities vs.

Products

Commodities
Products
Compositional
Performance
spec
spec
Generic
Differentiated
Low margin
High margin
High volume
Often low
Process-centered
volume
Productcentered

Process-Centered Company to
Product-Centered Company

Source: Stephanopoulos, 2004

Source: Stephanopoulos, 2004

Source: Stephanopoulos, 2004

Typicals companies

Unilever
P&G
Dow
Merck
LOreal
Indofood
Kalbe Farma
Nestle
Martha Tilaar
etc

Chemical Engineering
Design Trend

What is engineering design?

The process of applying various techniques and
scientific principles for the purpose of defining a
device, a process or a system in sufficient detail to
permit physical realization.
The design engineer makes choices based on a
thorough understanding of the engineering
fundamental, feasibility constraint, reliability, cost,
manufacturability, and human factors.
Good design requires experience, knowledge and
a considerable amount of intuition.

Product and Process

Development

Design
Objectives
determine the goal
determine all relevant factors
see the big picture
focus on critical issues
economic objective function + ecological,
social

Characteristic of
Design
Emphasis on synthesis, analysis & evaluation
Creative, Interactive and Iterative,
Problem statement ill-posed and open-ended,
Team-oriented and multi-disciplinary,
More than one right answer,
improve or new chemical product,
Always performed with an eye toward
the ultimate benefit, generally economic.

Design Thinking Framework

New Approach of Design

Gani, 2009

Similarities & Differences

Process Design

Product Design

Product is specified but

process is not

Neither product nor process is

specified

Focus on models of
manufacturing process

Focus on models of product

properties

Search technique to select

among process alternatives

Search technique to select

among product alternatives

Goal is lowest cost

manufacturing process

Goal is added value through

enhanced product properties

Chemical Process vs. Product

Design
Process Design

Product Design

Batch vs. Continous

Process

Identify Customer
Needs

Inputs and Outputs

Generate Ideas to
Meet Needs

Reactors and
Recycles

Select Among Ideas

Separation and Heat

Integration

Manufacture Products

Chemical Product
Design

Why CPD Is Important

Changes in the Chemical
Industry
Changes in Employment
Changes in Corporate
Culture

Trend affecting ChE

employment

Cussler & Wei, AIChE J, 49 1073

Chronological of chemical
product engineering as a
discipline within chemical
engineering

What is CPD?
New specialty chemicals that provide a
specific benefit, i.e. Pharmaceuticals
Microstructures of product, rather than
molecular structures, creates value:
processed foods, household products,
personal care products i.e. Paint and Ice
Cream, margarine, shampoo, toothpaste,
Devices that effect chemical changes, i.e.
Blood Oxygenator in Open Heart Surgery

Typical product forms and

Examples

Moggridge, 2006

Relationship between system

composition, processing and
product function

Broekhuis, 2012

Formulated products:
dispersed microstructured
materials

Broekhuis, 2012

Process-Property-Processing
Relations

Broekhuis, 2012

Chemical Product Pyramid

Moggridge, 2006

Concepts of Property Function,

Process Function and Usage
Function

Moggridge, 2006

Classification of product development

activities by phase
and by task

Cheng, 2009

The Product Design Procedure

Needs
Ideas
Selection
Manufacture

What needs should the product

fulfill ?
What different products could
satisfy these needs ?
Which idea are the most
promising ?
How can we make the product in
commercial quantities ?

The Product Developmet

Procedure

Cheng, 2009

The Industrial Design

Process

Product Development Process

Customer Needs Process

Source: Hey et al, 2006

Product Specification

Product Specification

Idea/Concept Generation

Concept Selection

The goal of concept selection is not to

select the best concept
The goal of concept selection is to
develop the best concept.

Manufacturing

Engineering Economics
Time value of money
Quantitative measures of
profitability
Estimation of costs
Systematic comparison of
alternatives

Entrepreneurship

Component of Innovation
Ecosystem

Technology S-curve

Three economic objectives for

entrepreneurship

Entrepreneur is individual whose function is to create new combinations

of ideas, products and markets for an economy

Enterprise and business

market relationship

Ralating Sectors of Economic

objectives

Place of the Designers

Teamwork

Thank You