cairo university faculty of engineering chemical engineering department introduction to chemical...
TRANSCRIPT
Cairo UniversityFaculty of Engineering
Chemical Engineering Department
Introduction to Chemical Engineering
Chapter 1INTRODUCTION
October 2009
contents
1. General
2. What is a chemical engineer ?
3. What is special about chemical engineers?
4. Chemical engineers ten Greatest Achievements
5. Where you will get a job ?
6. Summary
7. Course outline
1. General
• Chemical engineering is one of the big four branches of engineering: civil, mechanical, electrical and chemical
• Chemical engineering is well established in Egypt ( see next slide )
• Chemical engineers are very well recognized in North America and Europe
Chemical Engineering Departments in Egypt
Cairo University1942
Alexandria University1946
Menya University 1978
Military Technical College 1962
10th of Ramadan Technical Institute 1990
Al Sherook Academy 1998
2. What is a chemical engineer?
We will answer the question after presnting two illustrative examples
Illustrative example 1
A chemist working in the research and development (R&D) department in a pharmaceutical company discovered a process for producing a new valuable substance C. The reaction he applied is as follows:
A + B C + unreacted A + unreacted B
The work of the chemist in the Lab may be illustrated as follows:
Lab Glassware
Inputs Process Outputs
10ml A
10ml BReaction
70o C
Heat Energy
Cooling
Filtration
Drying
Warm tap water
(Filtrate)
Unreacted A + B
Vapors
Product C19 m / batch
Heat energy
Cold tap water
Solid C
Inputs Description of Work in the Lab Outputs
10ml A10ml B
Heat energy
Tap waterfor Cooling
Filteration
Drying
Substance C
Filtrated to Sink
Product D one gram
Tap water to sink
Precipitated C
Glass rod for mixing
From laboratory scale to industrial scale
After a lot of discussions and studies (?), the company decided to build a plant to produce substance C with a production capacity of 1 ton/day.
lab scale: 1 gm/dayindustrial scale: 1,000,000 gm/dayscale up factor: 1,000,000
In the lab,a glass beaker isused as a reactor
Industrial reactor
Industrial size Chemical Reactor
Storage of raw materials
Liquid storage tank
Industrial dryer
Steam-tube rotary dryer
3. What is special about chemical engineers?
Chemical engineers master the process design required for the production of materials we use in our daily life.
They are involved in all phases of technology development:
IDEA APPLICATION of SCIENCE MANUFACTURE
• Physical, chemical, biological & engineering science• Economics, business, management science
Chemical engineers are described as the “universal engineer” because they have a broad knowledge of:
Chemical engineers design, test, scale-up, operate, control, and optimize "unit operations“ of a process, such as distillation, mixing, and reactions.
Only chemical engineers use chemistry along with mathematics, physics, biology to solve technical problems in a safe and economical fashion.
Chemical engineering science uses mass, momentum, and energy transfer along with thermodynamics and chemical kinetics to analyze processes and improve them.
Only chemical engineers develop chemical and biochemical processes that turn raw materials into valuable products.
4. Chemical engineers ten Greatest Achievements
1. Splitting of the atom and isolating isotopes. 2 . Mass production of cheap plastic. 3 . The development of the "Unit Operations" of the human
reactor 4 . Low price, high volume production of wonder drugs for
the masses.5. Synthetic fibers.6 . Liquefied air and its separation into pure constituents. 7 . Environmentally conscious engineering 8 . Chemical fertilizers, food processing, Biotechnology of
food production.9 . Petroleum processing 10. Synthetic Rubber.
5. Where you will get a job ?
Products and Processes
• Consumer ProductsFood, water, clothing, medicines, health & beauty aids, fuels, lubricants
• Commodity ChemicalsOxygen, water, sulfuric acid, ammonia, chlorine, lye (soap), ethylene oxide, plastics, rubber
• Electronic/Optical Matls.High purity silicon, compound semiconductors, thin films, optical polymers
• Special materialsBiomaterials (prostheses), Nylon, Kevlar, Teflon
• ProcessesLarge scale chemical plants continuous processes that make commodity chemicals at low cost($100–500 million)
Intermediate scale plants for specialty chemicals($10–100 million)
Small scale batch processes for biomaterials and bioengineering($1–10 million)
SOME SUB-CATAGORIES:
Pharmaceutical Engineering Plastics and Polymer Engineering Petroleum Engineering…
Chemical engineers provide the skills needed to develop new polymers for medical devices, powerful new alloys for aircraft, components for the development of computer and other electronics industries. Health care will require new manufacturing processes for pharmaceutical products and surgical procedures.
Chemical engineers are in many industrial sectors
Bachelor's Master's Doctor'sChemical Engineering $46,900 $52,100 $67,300Electrical Engineering $45,200 $57,200 $70,800Mechanical Engineering $43,300 $51,900 $64,300Civil Engineering $36,100 $42,300 $58,600
Source: "National Association of Colleges and Employers, 1999 Survey"
Note that BS chemical engineers are loosing their salary advantage
USA data: 1999 Entry Level Wages Based on Degree Earned
Bachelor's Master's Doctor'sChemistry $29,500 $38,500 $59,300Source: "ACS Survey of recent graduates, 1998"
USA data: 1998 Entry Level Wages Based on Degree Earned
http://www.aiche.org/careerservices/library/pdf/salary080202.pdf
Please read this article:
6. Summary
• Chemical engineering is the application of science, mathematics and economics to the process of converting raw materials or chemicals into more useful or valuable forms.
• Chemical Engineering largely involves the design and maintenance of chemical processes for large-scale manufacture. Chemical engineers in this branch are usually employed under the title of process engineer.
(Cnt’d) Summary
The individual processes used by chemical engineers (eg. distillation or chlorination) are called unit operations and consist of chemical reaction, mass-, heat- and momentum- transfer operations. Unit operations are grouped together in various configurations for the purpose of chemical synthesis and/or chemical separation.
(cont’d) Summary
Three primary physical laws underlying chemical engineering design are Conservation of mass, Conservation of momentum and Conservation of energy. The movement of mass and energy around a chemical process are evaluated using Mass balances and energy balances which apply these laws to whole plants or a single unit operation.
In doing so, Chemical Engineers use principles of thermodynamics, reaction kinetics and transport phenomena.
(cont’d) Summary Chemical engineers are now engaged in the development
and production of a wide range of products, as well as in commodity and specialty chemicals. These products include high performance materials needed for aerospace, automotive, biomedical, electronic, environmental and military applications. Examples include ultra-strong fibers, fabrics, adhesives and composites for vehicles, bio-compatible materials for implants and prosthetics, gels for medical applications, pharmaceuticals, and films with special dielectric, optical or spectroscopic properties for opto-electronic devices. Additionally, chemical engineering is often intertwined with biology and biomedical engineering.
7. Course Outline
1. Introduction
2. History and basic concepts
3. Product design
4. Process design
5. Plant design
6. The sugar industry
7. The petrochemical industry
(Contd.) Course Outline
8. Energy, fuels and environmental problems
9. Biotechnology
10. Biomedical engineering applications
11. Cleaner production
12. Overview of the chemical process industry: past , present and future