Orientation
1.1 Why a chemical engineer needs expertise in process technology ?
A process engineer at operation in chemical plant shall have a deeper understanding of the technology on which the process plant is built to produce the profit making chemicals. A chemical engineer with sound knowledge in process technology has the following distinct advantages:
a) |
Ability to clearly distinguish the functional role and importance of various processes and operations in the process plan |
b) |
Technical knowledge with respect to the selection of important parameters such as Temperature, Pressure and underlying physical principles of a process. |
c) |
Ability to distinguish various process streams and their conditions of operation (Temperature, pressure and phases) |
d) |
Basic knowledge for process troubleshooting and necessary safety precautions associated to a process/operation. |
1.2 How to master fundamentals of process technology?
To master chemical process technology five crucial steps are involved namely:
a) |
Raw-Materials and reactions: A chosen process route to manufacture desired chemicals with appropriate purities will eventually lead to preparing a list of raw-materials and utilities. Thereby, prominent reactions can be also known. |
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Conceptual process flow-sheet: A conceptual process flow-sheet where a chemical engineer has an abstract representation of the actual process flow-sheet will enable quicker learning. A conceptual process flow-sheet typically constitute the following attributes: • Raw-material purification (Solid-fluid operations such as cyclone separators, ...bag filters etc.) • Raw-material processing (Heat exchange operations such as furnace ...heating, cooling etc.) • Raw-material to product transformation (Reaction operations using CSTR, ...PFR, PBR and Batch reactors) • Product purification (In separation processes such as flash, distillation, ...absorption and extraction) • Product processing (heat exchangers, phase change units) • Recycle of un-reacted raw-materials as recycle streams to the reaction ...operations. • Technological know-how of each unit operation/process to eventually identify its functional role in the process flow-sheet • Temperature, pressure and composition of streams entering the unit ...process/operation • Temperature, pressure and composition of streams leaving the unit ...process/operation • Phases of various streams entering and leaving the unit process/operation • Associated waste and environmental hazardous products generation |
c) |
Process intensification in the form of heat-integration, stream utilization and waste reduction and multiple recycle streams: These options are in fact optional and they enrich the energy enhancement and waste reduction efficiency of a process plant. Originally, chemical plants developed without such process intensification policies have been subjected to rigorous research and case study investigations to identify opportunities for cost reduction and better energy/waste management. |
d)
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Additional critical issues related to various unit operations/processes • Cost reduction approaches/process economics: How the operating variables (such as temperature, pressure, flow-rates, reflux rates, heating rate etc.) affect the cost of the unit operation/process • Safety issues: What safety issues are most relevant and need frequent ...monitoring |
e) |
Alternate technologies: For a desired function of a process unit, can thereby alternate technologies that could reduce the cost and even then provide the same functional role and desired flow rates and compositions of the emanating streams. |
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