Rafiqul Gani CAPEC KT Consortium Department of Chemical amp Biochemical Engineering Technical University of Denmark DK2800 Lyngby Denmark College of Control Science amp Engineering ID: 760512
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Slide1
A multi-layered view of chemical engineering
Rafiqul
Gani
*
CAPEC KT Consortium
Department of Chemical & Biochemical Engineering
Technical University of Denmark, DK-2800
Lyngby
, Denmark
*College of Control Science & Engineering
Zhejiang
University
,
Hangzhou
310027, China
rag@kt.dtu.dk
http://www.pseforspeed.com/
Slide2What is chemical engineering?
Chemical engineering is the application of science, mathematics and economics to the process of converting raw materials or chemicals into more sustainable forms. The terms economics & sustainability are very important here.
Energy
Sustainability
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Slide3What chemical engineers do? Highlights
Work with unit operations for purposes of chemical synthesis and/or separation (chemical reaction, mass-, heat- and momentum- transfer operations)Apply physical laws of conservation of mass, energy and momentumApply principles of thermodynamics, reaction kinetics and transport phenomenaSolve problems – design & operate processesMore than just process engineering – applies chemical knowledge to create better materials and products that are useful to our modern society
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Slide4A multi-layered view of
ChE: Core layer
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Core of chemical & biochemical engineering
deals with conversion of raw materials to useful products; finding the optimal synthesis routes and operating the processes for their designed applications, and through the use of science, mathematics, economics, ….
Slide5Where did this get us?
Fertilizers
Vitamins
Colorants and
coatings
Plastics
Fue
l
Electronics
Pharmaceuticals
Detergents
Nutrition
Healthcare
Mobility
Communications,
Entertainment
Clothing
Housing
We are the master of the planet earth
. . . .
. . . .
Positive contribution to the development of our society
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Slide6Classification of the key products in ChE
CommoditiesMoleculesMicrostructuresKeyCost-ManufacturingSpeed-SelectionFunction-NeedBasisUnit OpsChemistryMicrostructureRiskFeedstockDiscoveryScience
Traditional ChE: Convert resources to commodities?
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Slide7The future is unclear! Risky feedstock
Resources
Resources
ChE
Fight for survival!
Adopted from Cussler (2011)
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Slide8Classification of the key products in ChE
CommoditiesSingle SpeciesMulti SpeciesKeyCost-ManufacturingSpeed-SelectionFunction-NeedBasisUnit OpsChemistryMicrostructureRiskFeedstockDiscoveryScience
ChE is extending to design of single species products
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Slide9For single species products, “selection” is key
46 Kilos = $800 M
Adopted from Cussler (2011)
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Slide10Classification of the key products in ChE
CommoditiesSingle SpeciesMulti SpeciesKeyCost-ManufacturingSpeed-SelectionFunction-NeedBasisUnit OpsChemistryMicrostructureRiskFeedstockDiscoveryScience
ChE is also extending to design of multi species products
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Slide11Scientifically specified
Consumer reactions
For multi species products, ”need” is the key
Jet-fuel blend
Gasoline blend
Liquid formulations & emulsions
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Slide12Role & scope of ChE
What is the role of Chemical & Biochemical Engineering in “commodity” industry vs. “new emerging” technologies?
What is the future scope for fundamental contributions in Chemical & Bio-Chemical Engineering ?
Value preservation vs. Value creation
Engineering vs. Science
3. What are the major real world challenges Globalization-Environment (energy, water, health, food)
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Slide13A multi-layered view of ChE: Interface layer
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The core, however, needs to be supplemented by appropriate levels of science and engineering to find sustainable and innovative solutions. Sustainable and innovative solutions can be found through an appropriate mix of science-engineering
Slide14Current & future challenges
Sustainability Issues: Current and future survival
6-7 x
5-6 x
3.5 x
7 x
Increase
Global GDP growth over next ~50 years
(in constant dollars)
Production capacity for most commodities
(steel, chemicals, lumber, etc.)
Energy demand
Water demand
Electricity demand
Increase
GHG emissions
Increase in water, energy & commodities demand
World population is expected to reach 11 billions by 2050
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Adopted
from
Siirola
, PSE-2012
Slide15Is our future sustainable? The challenge facing us
Only 25% converted; must be > 40% (
Driolli
2007)
Convert resources to products
Use energy, water, ….
Environmental Impacts (GWP, OD, HTTP, …)
Produce waste
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Slide16Not threatened but our survival maybe is threatened unless we do something!
Our position as the master of planet earth?
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Slide17A multi-layered view of ChE: Connecting layer
Sustainable solutions (water, energy, resources)
Innovative solutions (process, product)
Science
Engineering
Application (industrial development)
Grand challenges-opportunities
Education
Society
Operation/Design
(production)
Processing Routes
(reaction; separation; mixing; heating-cooling; etc.)
Raw Materials
(resources)
Products(needs)
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The
overall objectives
are
to serve the society
through
educating the necessary engineers who can apply their education-training for industrial development taking advantage of the opportunities available and addressing the challenges being faced
Slide1818
What to make and how to make?
Q
uestions:what, why & when?
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Zhang, Babi & Gani, Annual Rev of Chem & Biomedical Eng, 2016
Slide19Need for integrated multidisciplinary approach
Exper
im
ents
R
E
ALITY
S
im
ulations
VIRTUAL
REALITY
P
rovide realistic model parameters
Verify theoretical solutions
System under study
Optimized design?
Model system
Optimized design?
G
u
idance and insights for experiments
Solution approaches
̶ Integrated modeling, experiments and synthesis̶ Ability to find predictive- innovative and more sustainable solutions
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Slide20Can the current methods, tools technologies deliver?
Can our current methods and tools solve the problems of our interest? Or, do we need a new class of software tools that promote innovation?
Well-known PSE tools: ASPEN, gPROMS, HYSIS, PROII, ChemCad, ….(design, optimization, control, plan-schedule operations, …)
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Slide21Need for innovation in process-product design
Eastman Chemicals
Methanol
+
Acetic Acid = Methyl Acetate + Water
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How to find new and significantly better unit operations?
Slide22Development of ChE – new directions
Probe the frontiers of technological innovations to bring New categories of abundant resourcesSubstitute and/or improve resources that become scarceDeliver sustainable solutions (energy, water, food …)Contribute to staving off disasters (global climate change, a viral pandemic, oil spills, …)3rd Paradigm (Integration of process-product-phenomena)
Unique opportunities and formidable challenges
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Slide23Necessary shift in education - 1
Need to keep core Chemical Engineering Knowledge; Need to emphasize fundamentals: basis is life-long learning2. Need to modernize curriculum and add flexibilityIncrease exposure at molecular levelIncrease exposure to energy (alternative/renewable) and sustainability issuesExpose students to new process technologyIntroduce product design as complement of process designEmphasize process operations, enterprise planningIncrease link to other industrial sectors (pharma, electronics)
Adopted from Grossmann 2014
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Slide24Necessary shift in education - 2
Adopted from Grossmann 2014
3. Need to recognize that “bio-area” & “nano-area” will be important but not dominant force in Chemical Engineering4. Environmental Engineering increasingly important and requires chemical engineering (water use efficiency, pollution control, chemical substitution, …) : Civil Eng. ownership?5. Need closer interaction with industry; otherwise risk being irrelevant6. Need to provide excitement to recruit the very best young people to join Chemical Engineering
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Slide25Are we now entering a golden age for ChE?
Adopted from Phil Westmoreland’s* 5 reasons
Manufacturing’s shift to emphasize processes and properties (smart manufacturing)New abundance of hydrocarbon resources in USA, China & other locations (a game changer)Biology’s turning into a molecular science (multi-disciplinary)Computing, evolved into a cyberinfrastructure (knowledge and data management – big data)ChEs’ breadth and problem-solving approaches (contribute to the society)
* President of the AIChE, 2013
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Slide26Conclusions & future directions
Need to adapt to the needs of the modern society (questions of energy, water, environment, sustainability, responsibility, ... should be incorporated in the study)Courses need to adopt (introduction of new ideas, new methods, new tools, ....)Balance between engineering-science; commodity-value added; core-new need to be found (different solutions are possible)
ChE’s positive contribution to the modern society through P3I
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Slide27Conclusions & future directions
Barcelona Declaration, 2017
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An increasing world population, in a world of finite natural resources, requires ever more innovative engineering to solve problems and produce new and better products with a negligible environmental footprint. Chemical engineering and related sciences and technologies must play a key role in meeting future societal needs.
We
, as chemical and biochemical engineers,
need to renew
our commitment to use our skills to improve the quality of life, foster employment, advance economic and social development and protect the planet through sustainable development
.
Slide28Conclusions & future directions
Barcelona Declaration, 2017
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Promote research and development as a fundamental pillar and encourage technology development to achieve a planet able to sustain a growing population, while improving quality of life.Facilitate global dissemination of chemical and biochemical engineering technical knowledge and industrial best practices, striving to bring together academia and industry worldwide.Promote conservation and care of global resources, health, safety, and the environment.Promote the highest standards of professional ethics and conduct for chemical engineers worldwide, to safeguard the public.
We should agree to:
Slide29ChE is a problem solver not a problem creator!
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If I change one molecule of this useless & polluting product, we can make an excellent hair-spray!
Chemical engineer