Contents

Cover

Preface

Foreword

Acknowledgements

Chapter 1: Introduction

1.1 Definition of Chemical Engineering
1.2 It is the Broadest Branch of Engineering
1.3 Chemical Engineering – a General Purpose Technology
1.4 Relationship Between Chemical Engineering and the Science of Chemistry
1.5 Historical Development of Chemical Engineering
1.6 Anatomy of a Chemical Engineering Plant

Chapter 2: Chemical Engineering Basic Education and Training

2.1 Introduction
2.2 Chemical Engineering Education Model
2.3 Objectives of Chemical Engineering Education
2.4 Academic Shift from Science to Engineering
2.5 Chemical Engineering Core Subjects and Applications
2.6 General Skills in Chemical Engineering Education
2.7 New Chemical Engineering Hire
2.8 Registration of Engineers

Chapter 3: Chemical Engineers’ Areas of Expertise

3.1 Introduction
3.2 Energy and Sustainability Segment
3.3 Food Segment
3.4 Biomedicine (BME)/Biotechnology/Bioengineering Segment
3.5 Electronics Segment
3.6 Materials Segment
3.7 Space Program
3.8 The Environment Segment
3.9 Summary of Industry Segments Served by Chemical Engineers

Chapter 4: Career Diversities in Chemical Engineering

4.1 Introduction
4.2 Career Development Leading to Specialization
4.3 Chemical Engineering Job Titles/Options
4.4 Chemical Engineering Professional Critical Success Factors

Chapter 5: Design and Chemical Engineering Practice

5.1 Introduction
5.2 Chemical Process and Plant Development Steps
5.3 Construction, Pre-Commissioning, Commissioning & Startup
5.4 Case Study of Chemical Engineering Equipment Design – Horizontal KOD Liquid-Vapor Separator
5.5 Economic Study of a Chemical Engineering Process
5.6 Case History Related to the Development of a New Chemical Process

Chapter 6: Chemical Process Safety Engineering and Management

6.1 Introduction
6.2 Chemical Engineering Design for Process Safety
6.3 Process Hazard Analysis Techniques
6.4 Process Safety Management

Chapter 7: Sustainability in Chemical Engineering Design

7.1 Introduction
7.2 Sustainability Model
7.3 Sustainability in Chemical Engineering
7.4 Chemical Engineering Sustainability Design and Research Problems

Chapter 8: Chemical Engineering Computer Software Tools and Applications

8.1 Introduction
8.2 Development of Chemical Engineering Computer Software
8.3 Process Engineering Design Software (HYSYS and PRO II)
8.4 Statistical and Numerical Analysis Software
8.5 Computer Programming and Control Software (MATLAB and Visual Basic)
8.6 Computer-Aided Design & Drafting (Auto-CAD)
8.7 Piping and Equipment Design Software
8.8 Others

Chapter 9: Graduate Programs in Chemical Engineering

9.1 Introduction
9.2 Requirements for Graduate Program in Chemical Engineering
9.3 Options in Chemical Engineering Postgraduate Programs
9.4 Chemical Engineering Research Needs and Opportunities

References

Index

End User License Agreement

List of Illustrations

Chapter 1

Figure 1.1.1 Crude Oil Refinery
Figure 1.1.2 Chemical Engineers maintain and run plants.
Figure 1.1.3 Chemical engineers design, construct and operate plants
Figure 1.4.1 Chemical Engineering Illustration
Figure 1.4.2 From Chemistry Laboratory to Large-Scale Production.
Figure 1.4.3 Relationship between Chemical Engineers and other Scientists.
Figure 1.4.4 A Chemist Working in the Laboratory
Figure 1.4.5 A Chemical Engineer in the Plant.
Figure 1.5.1 Evolution of Chemical Engineering.
Figure 1.5.2 Men that Steered Chemical Engineering Discipline
Figure 1.5.3 Kenneth Bingham Quinan
Figure 1.5.4 A Process unit of petrochemical plant under construction at Lagos.
Figure 1.6.1 Inside View of a Gas Processing Plant.
Figure 1.6.2 Front View of a Gas Processing Plant.
Figure 1.6.3 Anatomy of a Process Plant.
Figure 1.6.4 Plant Gas Metering unit.
Figure 1.6.5 Process Interconnecting Piping.
Figure 1.6.6 Gas Turbine Power Generator and Power Control Section of a Plant.
Figure 1.6.7 Typical Chemical Plant Laboratory
Figure 1.6.8 An Automation Engineer Inspecting Cable Terminations.
Figure 1.6.9 Process Control Room.
Figure 1.6.10 Process Control Field Instruments.
Figure 1.6.11 Plant units and valves.
Figure 1.6.12 Flare Unit of a Plant.
Figure 1.6.13 Engineering Office Meeting Room.
Figure 1.6.14 Engineering Design Office.
Figure 1.6.15 Effluent waste disposal Plant recently Commissioned in Port Harcourt.

Chapter 2

Figure 2.2.1 Chemical Engineering Undergraduate Student
Figure 2.4.1 Structure of Chemical Engineering Curriculum.
Figure 2.4.2 Chemical Engineering Core Subjects.
Figure 2.4.3 A food plant
Figure 2.5.1 A chemical reactor
Figure 2.5.2 A continuous stirred tank reactor (CSTR)
Figure 2.5.3 A Nuclear Reactor
Figure 2.5.4 Chemical process plant where thermodynamic principles are applied
Figure 2.5.5 Fluid transport system
Figure 2.5.6 Silicon Carbide Shell and Tube Heat Exchanger – ideal for corrosive media
Figure 2.5.7 A LP Horizontal Separator.
Figure 2.5.8 Sulfate Removal System
Figure 2.5.9 Schematic of pressure-driven processes.
Figure 2.5.10 A Process control panel screen
Figure 2.7.1 On-the-Job Training of New Chemical Engineering Hires.
Figure 2.8.1 In-person Training of Chemical Engineers.

Chapter 3

Figure 3.1 Chemical Engineers’ Areas of Expertise.
Figure 3.2.1 Energy Production
Figure 3.2.2 A Petroleum Refining Company in Niger Delta, Nigeria.
Figure 3.2.3 Biomass used for solid fuel
Figure 3.2.4 Clean Coal Processing Facility
Figure 3.2.5 Picture Depicting Renewable Energy
Figure 3.2.6 Nuclear Power Plant
Figure 3.3.1 A Food Processing Plant
Figure 3.4.1 Biopharmaceutical Laboratory
Figure 3.5.1 Professor Samson Jenekhe
Figure 3.5.2 Semiconductor Chip Laboratory
Figure 3.6.1 Plastic Product.
Figure 3.7.1 Rocket Powered by Propellants
Figure 3.8.1 The Environment.
Figure 3.8.2 Pollution Prevention hierarchy in order of decreasing preference. Source: Perry’s...

Chapter 4

Figure 4.2.1 Chemical engineering career options.
Figure 4.3.1 Picture of a Biodiesel Plant
Figure 4.3.2 Mini Refinery is designed by chemical process engineers
Figure 4.3.3 Refinery engineers work in a petroleum refinery
Figure 4.3.4 Fully Commissioned Chemical Plant
Figure 4.3.5 Maintenance Process Engineers at Work
Figure 4.3.6 Process Control Engineers
Figure 4.3.7 A Complex Chemical Plant: Process Safety Engineers Ensure Its Safe Operation
Figure 4.3.8 Biomedical engineer at work.
Figure 4.3.9 Biomedical engineers at work
Figure 4.3.10 R&D engineers frequently work in research and development or in quality...
Figure 4.3.11 A Pharmaceutical Plant
Figure 4.3.12 Project Engineer at Work
Figure 4.3.13 Critical Success Factors.

Chapter 5

Figure 5.2.1 Process unit (sludge catcher) of a gas plant.
Figure 5.2.2 Life cycle of a chemical/oil and gas plant (Scale-up Activity Model).
Figure 5.2.3 Process Design Route Consideration.
Figure 5.2.4 A process unit
Figure 5.2.5 A Mini Plant
Figure 5.2.6 Process Engineering Design Model.
Figure 5.2.7 Average Timeline for Process Plant Development.
Figure 5.2.8 Process Flow Scheme of Natural Gas Dehydration Plant. [157]
Figure 5.2.9 Conceptual Design Process.
Figure 5.2.10 A Process Flow Diagram.
Figure 5.2.11 A Computer-Generated Model for a New Gas Central Processing Facility (CPF)...
Figure 5.2.12 A Plot Printer
Figure 5.2.13 Symbols for Drawing Process Flow Diagrams.
Figure 5.2.14 Skeleton Process Flow Diagram (PFD) Sales Gas Compressor unit (Flow summary not...
Figure 5.2.15 A Projected PFD (taken by the author during a process design review meeting at Celle...
Figure 5.2.15 A Complex Process Plant. Credit: Schlumberger.
Figure 5.2.16 P&ID of Gas Blending and Mercury Removal Unit of a Gas Plant in Nigeria.
Figure 5.2.17 Construction of the Gas Blending & Mercury Removal Unit of a Gas Plant in...
Figure 5.2.18 P&ID Showing a Swamp Gas Sludge Catcher Unit of a Gas Plant in Nigeria.
Figure 5.2.19 Construction of the Gas Sludge Catcher Unit of a Gas Plant in Nigeria (See P&ID...
Figure 5.2.20 Sales Gas Compressor – An Example of Proprietary Equipment.
Figure 5.3.1 An ongoing process plant construction site.
Figure 5.4.1 Accidents due to over-pressurization of process units.
Figure 5.4.2 Schematic of a closed pressure-relief system.
Figure 5.4.3 Stages of Vapor/Liquid Separation.
Figure 5.4.4 Three-Phase Separator.
Figure 5.4.5 Forces on Liquid Droplet in Gas Stream.
Figure 5.4.6 Horizontal Flare Knock-out Drum.
Figure 5.4.7 Levels in a drum without boot.
Figure 5.4.8 Simplified cross-section of horizontal gas/liquid separator with the position and...
Figure 5.4.9 Dimensionless Chord Height, h* against Dimensionless Chord Area, A* (Source: Shell...
Figure 5.4.10 Drag Coefficient as a function of the Archimedes number.
Figure 5.4.11 Fabrication of the Flare KOD Separator (ASME Certified).
Figure 5.4.12 On-site Installation of the Flare KOD Separator.
Figure 5.5.1 A Petrochemical Plant Under Construction at Lagos, Nigeria.
Figure 5.6.1 Average Timeline of Project Phases.
Figure 5.6.2 Project High Level Schedule.

Chapter 6

Figure 6.1 Process Safety Model.
Figure 6.2 Process engineers design and operate chemical plants.
Figure 6.3 Safety, Alarm and Shutdown Protection for the Plant.
Figure 6.4 Active Safety Instrument Symbols.
Figure 6.5 Active Safety Instruments and their Connection to Process Equipment.
Figure 6.6 Steps to implement full HAZOP.
Figure 6.7 Safety Instrumented System Review (taken by the author during a design review meeting...

Chapter 7

Figure 7.1 The Environment.
Figure 7.2 Interaction between Three Key Sustainability Aspects.
Figure 7.3 Sustainability Model.
Figure 7.4 Product LCA
Figure 7.5 Sustainability in Chemical Engineering Model.
Figure 7.6 Dual Compact Flotation Unit.

Chapter 8

Figure 8.3.1 Simulation of Coal Gasification Using Aspen Plus. [158]
Figure 8.3.2 HYSYS simulation of a centrifugal compressor unit (Aspen Technology 2013). * The...
Figure 8.4.1 Distillation Column Simulation
Figure 8.5.1 Various Operating Conditions Data.
Figure 8.5.2 Conversions at Various Operating Conditions.
Figure 8.5.3 LINST function results.
Figure 8.6.1 Refinery Process Flow.
Figure 8.6.2 Products, Vol% against Conversion, %.
Figure 8.6.3 MATLAB Computer Program for Optimal Yield of Gasoline.
Figure 8.6.4 MATLAB Computer Program Solutions for Optimal Yield of Gasoline.
Figure 8.7.1 A 3D-CAD model of a proposed process plant.
Figure 8.8.1 Plant Piping Model
Figure 8.8.2 CAESAR II Model
Figure 8.9.1 A PowerPoint presentation in progress.

Chapter 9

Figure 9.1.2 Chemical Engineering (ChE) Graduate Program.
Figure 9.3.1 Areas of Specialization in Chemical Engineering Postgraduate Program.
Figure 9.2.1 Biochemical engineers research the engineering aspects of biological systems of...
Figure 9.2.3 Typical PSE Modules.
Figure 9.2.4 A Process Instrumentation and Automation Engineer
Figure 9.3.1 Chemical Supply Chain.
Figure 9.3.2 Process Systems Engineering Facility

List of Tables

Chapter 1

Table 1.1.1 Systems of Interest to Chemical Engineering.
Table 1.1.2 Services Provided by Chemical Engineers for Process Industries.
Table 1.5.1 Chronological History of the Emergence of Chemical Engineering.
Table 1.5.2 Chemical Engineering Unit Operations and Techniques.

Chapter 3

Table 3.4.1 World Consumption of Biotechnology-Based Chemicals - 2009...
Table 3.9.1a Summary of Industry Segments Served by Chemical Engineers.
Table 3.9.1b Summary of Industry Segments Served by Chemical Engineers.
Table 3.9c Summary of Industry Segments Served by Chemical Engineers.

Chapter 5

Table 5.2.1 Conceptual & Basic Process Engineering Deliverables.
Table 5.2.2 Basic Engineering Deliverables.
Table 5.2.4 Connotations Used for Field Instrument.
Table 5.2.5 Conventions Used for Identifying Process Equipment.
Table 5.2.6 Required Information Provided in a PFD Summary.
Table 5.2.6b Optional Information Provided in a PFD Summary.
Table 5.2.7 Information on a Heat & Material Balance Table.
Table 5.2.7a Information on a Heat & Material Balance Table.
Table 5.2.7b Information on a Heat & Material Balance Table.
Table 5.2.7c Information on a Heat & Material Balance Table.
Table 5.2.7d Information on a Heat & Material Balance Table.
Table 5.2.8 Equipment Summary Parameters.
Table 5.2.8b Equipment Summary Parameters.
Table 5.2.8c Equipment Summary Parameters.
Table 5.2.8d Equipment Summary Parameters.
Table 5.2.9 List of Detailed Engineering Design Deliverables.
Table 5.4.1 Determination of the separator design pressure.
Table 5.4.2 Recommended L/D ratio for horizontal drums.
Table 5.4.3 Input Data for KO Drum Separator Sizing.
Table 5.5.1 Terms that Constitute Fixed Capital Investment.
Table 5.5.2 Determination of Equipment Cost.
Table 5.5.3 Determination of Direct and Indirect Costs and Working Capital.

Chapter 6

Table 6.1 Features of HAZOP Study.
Table 6.2 HAZOP Guide Words.
Table 6.3 HAZOP Record Format.

Chapter 8

Table 8.6.1 Range of Operating Conditions, Feed and Product Yields in PRCL FCCU.

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Library of Congress Cataloging-in-Publication Data

ISBN 978-1-119-59210-5

Preface

This book offers a comprehensive overview of the evolution, essence, concept, principles, functions and applications of chemical engineering. It systematically describes the link between the foundational science of chemistry, biology and processes, to the engineering that delivers the required hardware functionality and products.

It further explains the distinct chemical engineering knowledge, which, although it originally stems from the synthesis of mechanical engineering and industrial chemistry, has given rise to a general-purpose technology and the broadest engineering field. The discipline is wide-ranging in scope and flexibility; it focuses at the molecular level—in terms of chemical, biological, and physical transformations that occur at this level, while at the same time focusing at the process and systems level—in terms of the process design and systems engineering that deliver the required product. Hence, the text in clear terms traces these broad facets of the field, the various industry segments served and the discipline’s contribution to global industrialization and well-being of humankind. Today, chemical engineering has evolved to such a unique knowledge area, which establishes the fact that the combination of a mechanical engineer and a chemist is not an alternative to a chemical engineer in an industrial setting.

The various features of a typical chemical engineering plant are described in this text. Moreover, it explains the education and training of chemical engineers and how the subjects studied in the class are integrated into the real-world of work. It likewise discusses career diversities in modern chemical engineering; and attempt is made to rate the level of chemical engineering knowledge being applied in the respective career options.

It further details the real activity model of the core chemical engineering knowledge base—process plant and equipment design, with a practical equipment design case study. Also, it shares the origin of chemical engineering information technology (the computer tools) and their applications. The book presents options in chemical engineering graduate programs, the requirements and how the options can provide graduates with advanced chemical engineering, process technology, production and managerial skills for exciting and challenging careers.

The current focus of the discipline is sustainable systems development through the integration of process safety, process systems engineering, process intensification, product design, life cycle analysis, cutting edge innovations in catalysis, materials, nanotechnology, molecular biology and advanced process economy. Thus, this book presents the global sustainability model and the unique role the frontiers of chemical engineering play toward ensuring sustainable solutions.

This book is expected to enhance students’ understanding and performance in the field and the development of the profession worldwide. Students, fresh chemical engineering graduates, new hires and professionals will find this text very useful. The information the trainee engineer needs to excel and cross the critical but complex stage of transitioning from the university to the real-world engineering practice are explained.

Several figures and tables help maximize reader insights into the concept of the discipline.

Foreword

The products in the world we use every day require the skill of a chemical/process engineer, who is trained to ensure the safe and profitable production of the chemicals and materials required to create the products such as food, medicine, fuels, plastics, clean water, clothing and entertainment system. Chemical/process engineers are very much at the forefront of improving the quality of lives of people in a safe environmental manner. Chemical engineering is a fascinating and challenging profession with a wide range of career opportunities. Chemical engineers combine a detailed knowledge of chemistry with understanding principles in order to design, construct and operate chemical process plants in an efficient, safe, sustainable and profitable manner.

U. Nnaji provides a comprehensive overview of chemical engineering linking the topics described in a concise and elucidated manner for students, graduates entering the employment market and professionals as a refresher in the subject. He further introduces the pertinent topics of process safety and sustainability with an in-depth knowledge of these subjects, and the application of process simulation in achieving reliable and monitoring operation of the process plants. This book would be most useful to students in this field, graduates and professionals as a refresher in the topics highlighted.

I highly recommend this book to these groups of individuals worldwide.

Kayode Coker

Acknowledgments

Let me start by thanking Dr. A. Kayode Coker, one of the world’s foremost chemical engineering author, for reading the manuscript and suggesting additional areas to cover in the book. Thank you so much.

This work is a result of two decades industrial experience and over a decade of thoughtful investigation on the subject during weekends and after work periods. Consequently, I encountered several individuals who either supported, encouraged and or proffered useful advice and suggestions. A few notable ones are Lee Webster, Contract Specialist, Onesubsea, Schlumberger; Stephen Lockett, SSA Geomarket PSD, Cameron, Schlumberger; Donald Ibegbu, NCD Manager, Schlumberger; Richard J. Emptage, Technical Director, Integrated Solutions, Early Engineering Engagement; and Rasheed Adebayo, Asset Manager, all Onesubsea, Schlumberger. Many thanks to Omongbai Ashion, Schlumberger Segment Sales Representative who was instrumental in keeping me on my toes during the final proofs of the work.

Others are former colleagues and managers at Saipem, who one way or the other supported or encouraged me. They include Guido Nardo, Giuseppe Piana, Joanna Ekwere, Arihar Singh, Ikechukwu Chukwura, Ihuoma Onwubuariri, Davide Rossi, David Egbedi, and Nuzzo Giampiero.

In the academia, I would like to thank Professor A. O. Kuye, and Dr. Ifeanyi Edeh, Chemical Engineering Department, University of Port Harcourt; Dr. Ifenyinwa Oranugu, biochemical engineer, Texas, USA and Ralph O. Edokpia, Associate Professor of Industrial Engineering, University of Benin; and many others, for their support.

I also want to express my gratitude to Nigerian Society of Chemical Engineers, RIVBAY, for granting me the opportunity to deliver several presentations.

Let me also express special thanks to Pastor Stanley Oseji, Dr. Charles Mbaba, Dr. Steve Ayinbuomwan, Hycinth Okonweze, and Louis Obiefuna for their immense support.

I am grateful to Phillip Carmical for his useful feedback and role in directing the publication of this book.

To my beautiful wife and kids – thanks for being there for me.

The book contains images of processes and equipment from many sources for which I am grateful.

Finally, and above all, I want to thank my maker for the inspiration to write this book.

Introduction to Chemical Engineering

For Chemical Engineers and Students

Preface

Foreword

Acknowledgments