Lecture 3: Process Engineering PDF

LECTURE 3 The Process engineering  What is a Process Engineer? Process Engineers design, implement and optimize chemical and biochemical processes, especially continuous flow ones on an industrial scale to turn raw materials into an end product (e.g. drugs, cosmetics, gasoline, beer, but...

LECTURE 3 The Process engineering  What is a Process Engineer? Process Engineers design, implement and optimize chemical and biochemical processes, especially continuous flow ones on an industrial scale to turn raw materials into an end product (e.g. drugs, cosmetics, gasoline, beer, butter, etc.). Process engineers are typically trained in chemical engineering. Process engineers make products that have to be mixed or cooked from a formula on a huge scale.  Principal areas of focus in process engineering Process engineering activities can be divided into the following disciplines:  Process design: includes synthesis of energy recovery networks, synthesis of distillation systems , synthesis of reactor networks superstructure optimization, design multiproduct batch plants, design of the production reactors for the production of radioactive materials, etc…  Process control: includes model predictive control, controllability measures, robust control, nonlinear control, statistical process control, process monitoring, thermodynamics-based control, denoted by three essential items, a collection of measurements, method of taking measurements, and a system of controlling the desired measurement. [  Process operations: include scheduling process networks, multiperiod planning and optimization, data reconciliation, real- time optimization, flexibility measures, fault diagnosis.  Supporting tools: include sequential modular simulation, equation-based process simulation, large-scale nonlinear programming (NLP), mixed-integer nonlinear programming (MINLP), global optimization.  Process Economics: includes using simulation software to find out the break even point, net present value, marginal sales, marginal cost, return on investment of the industrial plant after the analysis of the heat and mass transfer of the plant. [  Process Data Analytics: Applying data analytics and machine learning methods for process manufacturing problems.  Where Does a Process Engineer Work? Process engineers spend most of their time in an office or based onsite at industrial plants and other large-scale manufacturing locations. Depending on the role, they are often required to monitor or direct operations or be involved in the design or upgrading of existing facilities. They typically work in the following sectors.  Food and dairy  Chemical manufacturing  Petrochemical manufacturing  Agriculture processing  Mineral processing  Cosmetics  Pharmaceutical and biopharmaceutical manufacturing  Engineering consultancies focused on the above sectors  Engineering contractors focused on the above sectors  What Does a Process Engineer Do? A Process Engineer’s job can be extremely varied. Inlarger companies, Process Engineers may specialize in a niche area ‫المكان الالئق والمجدد‬but in smaller facilities, they can be responsible for a huge variety of tasks. These tasks can include: 1-Process Engineer design and develop continuous manufacturing process along with the layout and equipment for a new factory. This includes creating and setting specifications, developing, implementing and monitoring this equipment as part of the manufacturing system. 2- Process Engineers are responsible for commissioning and qualification of the new factory 3- Process Engineers modify and optimize equipment and processes that are already in place 4- Process Engineers use simulation software in the development of new processes 5- Process Engineers are responsible for completion of documentation to show and ensure compliance with both internal and external regulations