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• Chemical engg. core that defines the discipline and provides the basis
2 for quantification, integration, and relevance in problem solutions
Based on work, curricula can be divided into four major parts, not in the usual three
Complementary disciplines
(compulsory or electives)
Engineering Core
Basic Science
External training is a pre-requisite for the
engineering core topics, but will also have a content
of a general nature as well as topics needed for
further studies. It should naturally include
Mathematics, Informatics, Chemistry and Physics,
with ‘hands-on’ laboratory experience on all of them,
using without complex computer tools as aids to
mathematics.
Molecular transformations: the molecular Meso Scale
basis of chemical engineering. Students
recognize that properties can be changed by Macro Scale
changing structure via qualitative and
quantitative computation
Micro Scale
Multi-scale analysis: Application of
chemical engineering principles over
many scales of length and time Molecular Scale
Inflow Outflow
biology and integration
Increased emphasis on
Principal Development
CHEM ENGG PILLARS
Foundation of ChE
Thermodynamics
Reactive Process
Transport Phenomena
System Engg
PILLARS (Contd…)
SUBJECT DELIVERABLES
Foundations combines mass and energy balances, thermodynamics, separations, and product
design.
of ChE
introduces chemical engg. problem solving techniques from both a (traditional)
process centric & product-centric viewpoint.
spans from theoretical to applied allowing a simple route to problem-based
learning of concepts
Reactive Integrates reactor design, reaction kinetics, and advanced separation processes to
allow the comprehensive study of systems ranging from polymerization reactors to
Processes enzyme- Catalyzed metabolism to (bio-)artificial organs.
Systems The Dynamics and Modeling class is the first of a two part Systems Engineering
pillar sequence. This course covers dynamical analysis of process systems, process
Engineering control fundamentals, feedback, basic process modeling, and optimization.
The second course in this sequence is the Design course which formally combines
topics from all other pillars to allow both product and process design.
The development of mathematical models that afford a seamless transition from microscopic
to macroscopic levels (e.g., a commercial process) is a worthy goal, and much progress in this
direction has occurred in the past 10 years in areas such as computational fluid dynamics.
However, due to computational limitations and to some extent academic specializations,
process engineering(system Engineering) research has devolved into four more or less
distinct areas
1. Process design,
2. Structure property
relationships,
3. Process control,
4. Process operations
IDEAL SUBJECT MIXTURE
Elective 8%
Core 38%
Pure Science
30%
Humanities
Lab 12% 16%
To respond to the changing needs of the chemical and related industries a modern chemical
engineering has to satisfy both the market requirements for specific nano and microscale
end-use properties of products, and the social and environmental constraints of industrial
meso and macroscale processes. Thus an integrated system approach of complex
multidisciplinary, non-linear, non-equilibrium processes and phenomena occurring on
different length and time scales of the supply chain is required. That is, a good understanding
of how phenomena at a smaller length-scale relates to properties and behaviour at a longer
length-scale is necessary (from the molecular-scale to the production-scales). This has been
defined as the triplet "molecular Processes-Product-Process Engineering(3PE)" integrated
multiscale approach of chemical engineering.
Movie to demonstrate physical scales in nature
The unifying theme of multi-scale modeling and simulation arises naturally in the course of theoretically
investigating diverse problems in the areas of catalysis, solid state physics, fluid mechanics, nanomaterials, and
synthetic and biological polymers. Modeling methods that are currently used span the entire spectrum from ab
initio quantum mechanical calculations, through atomistic and mesoscale techniques, such as molecular
dynamics and Monte Carlo methods, to macroscopic and mean-field descriptions.
Time, s-
a trickle-bed reactor to micrometers in
turbulent flow. It may go to angstroms if
diffusion in Zeolites is considered. In
catalyst we may be interested in a single
molecule as a homogeneous catalyst or
millimeter size silica-alumina catalyst. At
the molecular/electronic scale , we have
the size of a single molecule and an
electron and various characteristic times
due to electronic motions.
Length and time scale covered in the multi-scale
analysis
Steps during development of process models
1020
TURBULENT ASTROPHYSICS
Moving in the
interior of stars
MECHANICAL ENGINEERING
RENOLDS NUMBER 1010 combustion ENVIRONMENTAL SCIENCE
Dispersion in atmosphere
OCEANOGRAPHY
Dispersion in ocean
CHEMICAL ENGINEERING
100
Chemical Reactors
PHYSIOLOGY
Mixing in blood vessels
BIOENGINEERING
Aeration in bioreactors
10-10 FOOD ENGINEERING
Blending of additives
POLYMER ENGINEERING
Polymer blending. GEOLOGY
Compounding Mixing in the
mantle of the earth
Laminar
10-20
10-6 100 106 1012
Length Scale, m
Mixing phenomena studied in diverse disciplines
Introduction to Scale up
Introduction
1. As population is increasing day by day, requirements are also
following the same path. Due to this there is need for the increase
of production. This is exactly where the study of scale up is
required.
2. Scale-up is generally defined as the process of increasing batch
size. Scale-up of a process can also be viewed as a procedure for
applying the same process to different output volumes. The term
“scale-up” means of increasing the dimensions while preserving
similar systems.
Increasing size
4. “scale-up is still not an exact science, but is rather that mix of
physics, mathematics, history and common sense that we call
engineering”. (by Matsen)
5. Now days, chemical engineers are faced with many research and
design scale up problems which are so complicated that they
cannot be solved by numerical mathematics. For example
processes involving fluids with temperature-dependent physical
properties or non-Newtonian flow behavior.
Fundamental mathematical models are becoming available due to an improved understanding of
microscopic and molecular behavior, which could ultimately lead to ab initio process design. This will
enable design of a process to yield a product (e.g., a polymer) with a given set of target properties,
predictable environmental impact, and minimum costs. Ideally one would want to be able to start with
a set of material properties and then reverse-engineer the process chemistry and process design that
gives those properties
Historically the chemical industry has used the following sequential steps to
achieve commercialization
steps (1) and (2) generally involve several types of
1. Research and development, experimentation, such as laboratory discovery, followed
by bench-scale experiments (often of a batch nature),
2. Scale-up, and then operation of a continuous flow or batch pilot
3. Design, and plant. It is at this level that models can be postulated
and unknown parameters can be estimated in order to
4. Optimization validate the models
3. Experimental Scale Up
• A carefully planned test campaign is needed to collect
data that adequately cover a wide range of the most
important operating variables, conducting the minimum
possible experiments.
• These laboratory-scale experiments should be held in a
wide range of conditions that cover those expected in the
commercial units, for five key operating variables space
velocity, temperature, pressure, composition, and particle
size. Initially, only one variable should be changed at a
time, keeping all the others constant.
Chemical Engineering Science and Design (48 hours)
ECH 3023 (3) Mass and Energy Balances I Florida State University
ECH 3024 (3) Mass and Energy Balances II
ECH 3101 (3) Chemical Engineering Thermodynamics
ECH 3266 (3) Transport Phenomena I
ECH 3274L (3) Transport Phenomena Lab
ECH 3418 (3) Separations Processes
ECH 3854 (4) Chemical Engineering Computations
ECH 4267 (3) Transport Phenomena II
ECH 4323 (3) Process Control
ECH 4323L (1) Process Control Lab
ECH 4404L (3) Unit Operations Lab
ECH 4504 (3) Kinetics and Reactor Design
ECH 4604 (4) Chemical Engineering Process Design I
ECH 4615 (3) Chemical Engineering Process Design II
ECH XXXX or BME XXXX (6) Chemical Engineering Electives (3 for Biomedical Engineering)
SOURCE: UNIV OF UTAH
CORE CIRRICULUM STRUCTURE
IDEAL CIRRICULUM STRUCTURE
Do’s of Scale Up
1. Operating philosophy :-Develop an overall pilot-plant operating philosophy and
guidelines for the minimum documentation required before a new process can be
run in plant equipment - for example, a detailed laboratory process description,
process safety information package.
2. Equipment logbooks :- Set up operating and maintenance log books for each major
piece of equipment in the plant (e.g., reactors, filters, dryers, pumps, hoses, etc.).
And write the data of all batches, cleaning operations, test results, and any
maintenance performed, beginning with the date of installation and qualification.
3. Sample database :- Set up a sample log book or database. Using any reasonable
numbering system, list in it every single sample collected in the plant for testing or
retention. Include batch number, step number, time collected, purpose, test results,
etc. This will become valuable information for future reference, and will help
ensure that important data are not lost. There may never be another opportunity to
generate many of the samples collected during scale-up batches.
2. Heating :-Never heat a reactor without agitation. It can create hot spots that can
erupt into violent boiling when the mixer is turned on or initiate unexpected
decomposition. Never stop the agitator until a reaction mixture has cooled to a
safe temperature.
6. Exotherms :-Try to avoid "all in and heat" operation (adding all reagents to the
vessel and then heating up). Because of diminished heat-removal capacity at
large scale, exothermic reactions can cause a thermal runaway. Exothermic
decomposition reactions may follow, putting the reaction beyond any chance
of operator control. Rapid gas evolution can compound the problem. It is better
to design reactions so they can be controlled by slow addition of a limiting
reagent at a rate that matches the equipment's cooling capacity. As a corollary
to this rule, never add a catalyst to a reaction mixture last.