what should every graduating chemical engineer know about
TRANSCRIPT
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W. David Harding – University of New Haven
Brian Harding – Mary Kay O’Connor Process Safety Center Texas A&M University
Peter Montagna – Henkel Corporation
What should every graduating chemical engineer know about process safety and how can we
make sure that they do?
Presented at 122nd ASEE Annual Conference June 16, 2015Based on paper #11636
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Motivation
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Motivation Part Two
• What are our responsibilities as ChE educators?
• Are current approaches reasonable?
• What chemical process safety topics are critical?
• What are good approaches to teaching these critical topics?
• What resources are available to support teaching of these topics?
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Manuscript Includes
• Discussion of the new program specific requirements
• Review of recommended chemical process safety topics
• Suggested strategies for implementing process safety into the undergraduate chemical engineering curriculum
• Review of information sources to:– Help chemical engineering programs choose appropriate content– Support instruction in process safety
• Suggestions for assessing the effectiveness of instruction
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What to teach?
The importance of process safety
How to characterize hazards associated with chemicals
Concepts of inherently safer design
Proficiency with at least one hazard identification procedure
Impacts of chemical plant incidents due to
releases and exposures
Familiarity with major safety
related regulations
How to mitigate hazards
Familiarity with hazard evaluation and risk assessment
Recommendations from SACHE, February 2010
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Challenges
• How and where to incorporate into the curriculum
• Who will lead the effort
– Adjunct with significant industry experience
– Faculty specializing in chemical process safety
– Faculty with specialized training
– Faculty with a general interest
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Primary Sources
• Text books to support chemical engineering instruction
– General design related text
– Texts that specialize in process safety
• Products produced by SACHE
• Products produced by CCPS
• E-learning products available through AICHE Academy
• Faculty expertise
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Possible Strategies
• Core Course
• Elective Course
• Core course with reinforcement throughout curriculum
• Integration throughout the curriculum
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University of New Haven Approach
• Develop a safety culture
• Disperse chemical process safety instruction throughout curriculum
• Focus on process safety in the unit operations laboratory
• Offer an elective course in chemical process safety
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Incorporation of SACHE ModulesMapping of SAChE Modules to Required Chemical Engineering
Courses at University of New Haven
Semester Course SAChE Module
4 Process Analysis Process Safety 101
5 Transport Operations IProcess Safety Lessons Taught from
Experience
5Chemical Kinetics and Reactor
DesignRunaway Reactions
6 Transport Operations II Safety in the Process Industries
7Chemical Engineering
LaboratoryRisk Assessment
7 Chemical Engineering Design I Chemical Reactivity Hazards
8 Mass Transfer Operations Dust Explosion Control
8 Chemical Engineering Design II Inherently Safer Design
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University of New Haven Process Safety Course
Overview of pertinent environmental and occupational safety & health regulations in the United States;
Fundamentals of toxicology and controls (engineering/administrative/PPE);
Modeling chemical releases; Reactive chemicals and processes; Fires/explosions (flammable liquids, combustible dusts) and their
prevention; Pressure relief sizing and sizing bases; Risk assessment, including Hazard and Operability Study; Accident/incident investigation; Safety Instrumented Systems and Inherently Safer Technologies.
Current text: Crowl & Louvar, Chemical Process Safety: Fundamentals with Applications, 3rd Ed.
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Assessing Student Learning Suggested Performance Indicators Related to Process Safety
Suggested Performance Indictor Related Course
Students can identify potential hazards from a process
flowsheet (analyze process flowsheet)Design
Students can describe the steps in a Hazards and
Operability ReviewDesign
Students can propose layers of protection to mitigate
process hazardsDesign
Students can describe conditions that are likely to lead
to a runaway reaction
Chemical kinetics and
reactor design
Students can analyze a chemical reaction scenario to
determine potential for runaway reaction.
Chemical kinetics and
reactor design
Students can determine the hazards associated with
operation of laboratory equipment and propose
measures to mitigate (or manage) hazards.
Unit operations
laboratory
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T2 Laboratories
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Wrap Up
As chemical engineering programs undergo reaccreditation they will need to demonstrate that they are integrating the program specific requirement relating to the hazards associated with chemical processes.
We authors hope that the information presented in the manuscript will serve as a resource to assist chemical engineering programs with development of an approach that fits their needs.