Introduction to Chemical Engineering

Uche P. Nnaji is a project manager at Schlumberger and has recently been appointed to lead a subsea integration alliance front end engineering design (FEED) project. He has a wide-ranging industrial experience spanning two decades, in the areas of process engineering and EPCI project management. He has been involved in the development of a couple of chemical gas plants from concept and has participated in design reviews at different locations in the world. Nnaji has worked for Shell Petroleum Development Company (SPDC) and Saipem. He has authored a previous book and has presented numerous papers. He is a registered professional engineer.

Preface xiii

Foreword xv

Acknowledgements xvii

1 Introduction 1

1.1 Definition of Chemical Engineering 1

1.1.2 Chemical Engineers 3

1.2 It is the Broadest Branch of Engineering 6

1.3 Chemical Engineering – a General Purpose Technology 7

1.4 Relationship Between Chemical Engineering and the Science of Chemistry 7

1.4.1 Chemical Engineers Take Chemistry Out of the Laboratory and Into the World 10

1.5 Historical Development of Chemical Engineering 12

1.5.1 Industrial Chemistry and Mechanical Engineering 13

1.5.2 Unit Operations 19

1.5.3 Chemical Engineering Science 22

1.5.4 Chemical Systems Engineering 23

1.6 Anatomy of a Chemical Engineering Plant 23

1.6.1 Overview 23

1.6.2 Process Units 25

1.6.3 Process Interconnecting Piping (Pumps, Piping & Valves) 27

1.6.4 Power/Electrical Unit 27

1.6.5 Process Laboratory 28

1.6.6 Process Control 29

1.6.7 Storage Tanks 31

1.6.8 Flare and Atmospheric Ventilation Unit 32

1.6.9 Workshop and Lay-down Area 34

1.6.10 Office Building and Others 34

1.6.11 Warehouse and Storage 35

1.6.12 Firefighting Unit 35

1.6.13 Water Generation Unit 36

1.6.14 Waste Treatment and Disposal Unit 36

2 Chemical Engineering Basic Education and Training 37

2.1 Introduction 37

2.2 Chemical Engineering Education Model 37

2.3 Objectives of Chemical Engineering Education 39

2.4 Academic Shift from Science to Engineering 40

2.5 Chemical Engineering Core Subjects and Applications 44

2.5.1 Chemical Reaction Engineering 44

2.5.1.1 Applications of Reaction Engineering 45

2.5.1.2 The Chemical Reactor 46

2.5.2 Thermodynamics for Chemical Engineers 49

2.5.2.1 Applications of Thermodynamics 50

2.5.3 Transport Phenomena (Transport Processes) 52

2.5.3.1 Applications of Transport Phenomenon 53

2.5.4 Separation Processes 55

2.5.4.1 Applications of Separation Processes 57

2.5.5 Process Dynamics and Control 60

2.5.5.1 Applications of Process Dynamics and Control 62

2.6 General Skills in Chemical Engineering Education 63

2.7 New Chemical Engineering Hire 63

2.7.1 Transitioning from the University to Professional Engineering Career 64

2.7.2 Job Assignment of a Trainee Chemical Engineer 65

2.7.3 Required On-the-Job Training and Skills 66

2.7.4 Expected Challenges for the New Chemical Engineer 68

2.7.5 Career Growth Path and Success Factors 70

2.8 Registration of Engineers 71

2.8.1 Institution of Chemical Engineers (IChemE) 72

2.8.1.1 IChemE Membership Grades 74

2.8.2 American Institution of Chemical Engineers (AIChE) 76

2.8.2.2 AIChE Membership Grades 77

3 Chemical Engineers’ Areas of Expertise 79

3.1 Introduction 79

3.2 Energy and Sustainability Segment 81

3.2.1 Petroleum Refining 82

3.2.2 Synthetic Liquid Fuels 84

3.2.2.1 Fuels from Biomaterials 84

3.2.2.2 Electricity Generation from Coal 86

3.2.3 Hydrogen Fuel 87

3.2.4 Solar and Wind Energy 88

3.2.5 Nuclear Energy 89

3.3 Food Segment 90

3.4 Biomedicine (BME)/Biotechnology/Bioengineering Segment 95

3.4.1 Biomedical or Tissue Engineering 95

3.4.2 Biotechnology-Based Chemicals 96

3.4.3 Pharmaceutical Engineering 97

3.4.4 Kidney Dialysis, Diabetes Treatment, and Drug Delivery Systems 98

3.5 Electronics Segment 99

3.6 Materials Segment 101

3.6.1 Biomaterials 103

3.6.2 Plastics Materials 103

3.6.3 Telecommunications Materials 104

3.6.4 Computer Chips Materials 105

3.6.5 New Researches 105

3.7 Space Program 106

3.8 The Environment Segment 108

3.8.1 Green Engineering 110

3.9 Summary of Industry Segments Served by Chemical Engineers 111

4 Career Diversities in Chemical Engineering 115

4.1 Introduction 115

4.2 Career Development Leading to Specialization 115

4.3 Chemical Engineering Job Titles/Options 118

4.3.1 Biochemical Engineer 118

4.3.2 Chemical and Process Engineers (Design Engineers) 119

4.3.3 Refinery Engineer 123

4.3.4 Chemical Development Engineer 124

4.3.5 Commissioning Engineer 126

4.3.6 Maintenance Engineer/Maintenance Planning Engineer/Process Maintenance Engineer 127

4.3.7 Process Control/Automation Engineer 129

4.3.8 Process Safety Engineer 131

4.3.9 Biomedical Engineer 134

4.3.10 Research & Development Engineer 136

4.3.11 Sales Engineer 138

4.3.12 Performance Control Engineer 139

4.3.13 Planning Engineer 140

4.3.14 Facilities Process/Plant Engineer 141

4.3.15 Pharmaceutical Engineer/Pharmaceutical Process Engineer 142

4.3.16 Site Engineer 144

4.3.17 Production Engineer 146

4.3.18 Pipeline Engineer 147

4.3.19 Petroleum (Production, Reservoir and Drilling) Engineer 149

4.3.20 Environment Engineer 151

4.3.21 Materials Engineer 152

4.3.22 Piping and Lay-out Engineer 153

4.3.23 Project Engineer 155

4.3.24 Cost Control/Cost Engineer 156

4.3.25 Contracts Engineer 158

4.3.26 Chemical Manufacturing Engineer 159

4.3.27 Quality Process Engineer/Quality Control Engineer 160

4.3.28 Others 162

4.4 Chemical Engineering Professional Critical Success Factors 163

5 Design and Chemical Engineering Practice 165

5.1 Introduction 165

5.2 Chemical Process and Plant Development Steps 166

5.2.1 General 166

5.2.2 Process and Technology Development 168

5.2.3 Engineering Design 177

5.2.3.1 General 177

5.2.3.2 Conceptual/Basic Engineering Design/Feasibility Study 178

5.2.3.3 Front-End Engineering Design (FEED) 185

5.2.3.4 Description of the Key Process Engineering Deliverables/Activities 187

5.2.3.5 Process Narrative/Description 197

5.2.3.6 PFD Review 198

5.2.3.7 Chemical Engineering Equipment Descriptions for PFD and P&IDs 204

5.2.3.8 Detailed Process and Engineering Design 208

5.3 Construction, Pre-Commissioning, Commissioning & Startup 217

5.4 Case Study of Chemical Engineering Equipment Design –Horizontal KOD Liquid-Vapor Separator 218

5.4.1 Introduction 218

5.4.2 Knock-Out Drum Separator Design 221

5.4.2.1 Scientific Principles Applied 221

5.4.2.2 Design Parameters 225

5.4.2.3 Design Data and Solution 228

5.4.2.4 Conclusion 241

5.5 Economic Study of a Chemical Engineering Process 241

5.6 Case History Related to the Development of a New Chemical Process 247

5.6.1 Conceptual and Front-End Engineering Design 247

5.6.2 Detailed Engineering Design and Construction 248

5.6.3 Pre-Commissioning and Commissioning 251

5.6.4 Plant Operation 252

6 Chemical Process Safety Engineering and Management 253

6.1 Introduction 253

6.2 Chemical Engineering Design for Process Safety 255

6.2.1 Selection of Inherently Safer Process Route 255

6.2.2 Process Design 256

6.2.3 Incorporating Process Safety into Process Equipment Design 259

6.2.4 Preventive and Protective Design Features 261

6.2.5 Safety Administrative or Procedural Control (Active Solutions) 264

6.3 Process Hazard Analysis Techniques 264

6.3.1 Hazard and Operability Study (HAZOP) 265

6.3.2 Process Safety Design Verification 273

6.4 Process Safety Management 274

7 Sustainability in Chemical Engineering Design 277

7.1 Introduction 277

7.2 Sustainability Model 279

7.2.1 Sustainable Raw Materials 282

7.2.2 Sustainable Manufacturing Process 283

7.2.3 Sustainable Consumption/Behavior 285

7.3 Sustainability in Chemical Engineering 286

7.4 Chemical Engineering Sustainability Design and Research Problems 290

7.4.1 Key Challenges 292

7.4.2 Technologies for Sustainability 292

8 Chemical Engineering Computer Software Tools and Applications 295

8.1 Introduction 295

8.2 Development of Chemical Engineering Computer Software 295

8.3 Process Engineering Design Software (HYSYS and PRO II) 297

8.3.1 HYSYS Process Engineering Design Software 297

8.3.2 PRO II Process Engineering Design Software 298

8.4 Statistical and Numerical Analysis Software 301

8.4.1 Engineering Computations Using Microsoft Excel 301

8.5 Computer Programming and Control Software (MATLAB and Visual Basic) 303

8.6 Computer-Aided Design & Drafting (Auto-CAD) 309

8.7 Piping and Equipment Design Software 311

8.8 Others 313

8.8.1 Presentation Software (Power Point) 313

9 Graduate Programs in Chemical Engineering 315

9.1 Introduction 315

9.1.1 Master’s Degrees 316

9.1.2 Doctoral-Level Degrees 317

9.2 Requirements for Graduate Program in Chemical Engineering 318

9.3 Options in Chemical Engineering Postgraduate Programs 319

9.3.1 Advanced Chemical Engineering with Biotechnology/Biochemical/Medical/(Bio) Engineering 320

9.3.2 Engineering Management in Chemical Engineering 321

9.3.3 Advanced Materials Engineering Option 322

9.3.4 Process Systems Engineering (PSE) Option 323

9.3.5 Chemical Process Engineering 325

9.3.6 Oil and Gas Engineering 325

9.3.7 Advanced Chemical Engineering with Polymer Engineering 326

9.3.8 Advanced Chemical Engineering with Structured Product Engineering (SPE) 327

9.3.9 Process Automation, Instrumentation and Control Option 328

9.3.10 Process and Equipment Design Option 329

9.3.11 Advanced Chemical Engineering with Information Technology and Management 329

9.3.12 Innovative and Sustainable Chemical Engineering 330

9.3.13 Catalysis, Kinetics & Reaction Engineering 330

9.4 Chemical Engineering Research Needs and Opportunities 330

References 337

Index 345