CH2089 Process Engineering 1

Chemical Industries
and
Chemical Engineers
 LECTURE TOPIC

Todays lecture will focus on the following topics:

1. Introduction Chemical 2 . Introduction of Chemical

Industries Engineers
 LEARNING OBJECTIVES

By the end of this course, the students should be able:

• Understand the chemical industries

• Understand the chemical engineers profession & its chemical

industries
 What is Chemical Engineering?

• At first, chemical engineering was related to trades

involving chemicals.
• In the latter half of the 18th century, chemical engineering
began to earn the status of an independent division of
knowledge.
• George E Davis is often regarded as the ‘founding father’ of
chemical engineering.
• The first chemical engineering course was delivered by
George at the University of Manchester in 1887 in the form
of 12 lectures covering various aspects of industrial
chemical practice

4
 The Struggle for Survival

• The chemical engineering profession began in 1888.

• To survive, chemical engineers had to claim industrial
territory by defining themselves and demonstrating their
uniqueness and worth. With this objective in mind, the
American Institute of Chemical Engineers (AIChE) was
formed in June of 1908.
• British Institution of Chemical Engineers (IChemE)
formed in 1992.
• Most Australian chemical engineers are members of
IChemE.

5
Learn about cement making plant, and identify the
key important features
Learn about crude oil processing plant and identify
the key important features
What is this plant and what do they process?
 DEFINATION-CHEMICAL INDUSTRY
The chemical industry comprises the companies that produce
industrial chemicals. Central to the modern world economy, it
converts raw materials (oil, natural gas, air, water, metals, and
minerals) into more than 70,000 different products.

Polymers and plastics, especially polyethylene, polypropylene,

polyvinyl chloride, polyethylene terephthalate, polystyrene and
polycarbonate comprise about 80% of the industry’s output
worldwide. Chemicals are used to make a wide variety of
consumer goods, as well as thousands of inputs to agriculture,
manufacturing, construction, and service industries.

http://en.wikipedia.org/wiki/Industrial_chemistry
CHEMICAL INDUSTRY COMPANIES

http://en.wikipedia.org/wiki/Industrial_chemistry
PETROCHEMICAL PRODUCTS
 CHEMICAL INDUSTRY COMPLEX

residential
production
Shipment product

Headquarters of the BASF Group – Ludwigshafen, Germany with over

160 chemical production plants and it is the largest integrated industrial
complex in Europe (.http://www.flickr.com/photos/basf/5122815290/
 CHEMICAL INDUSTRY COMPLEX

Aerial view of PETRONAS’s Petroleum Industry Complex in

Kertih www.encyclopedia.com.my
 PETRONAS is a fully integrated Petroleum Company and is ranked
among Fortune Global 500’s largest corporations in the world.
… involved in exploration & production, refining, gas processing and transmission, gas
liquefaction, manufacturing of petrochemical products, marketing and trading, and integrated
logistics.
CRUDE CRUDE OIL
OIL LPG
GASOLINE
JET FUEL
MARKETING DIESEL
OIL FACILITIES FUEL OIL
CONDENSATES

REFINING PETROLEUM
PRODUCTS

AROMATICS PETROCHEMICAL MTBE

ETHYLENE
POLYETHYLENE
CONDENSATES ROPYLENE
LPG POLYPROPYLENE
EXPLORATION & METHANOL
PRODUCTION AMMONIA
VCM
SALES GAS ETHYLENE
DERIVATIVES
PROCESSING
GAS
FERTILISERS

Supported by R&D, PIPED GAS

LNG
Technical Services, LNG
LIQUEFACTION
Education and
Training.
UNDERSTANDING OF A CHEMICAL INDUSTRY

Many products such as ammonia, nitric acid, sulfuric acid,

polymers etc are made in the respective chemical plants. As
a chemical engineers, your must familiar with the following
questions because you are directly responsible with the
production of the products:

• End product?
• Materials used?
• Type of process used?
• Product properties?
• Use of the product?
• Where to market?
 EXAMPLE: AMMONIA PRODUCTION

The Haber-Bosch process was developed by industrial chemist Fritz

Haber, and scaled up by chemical engineer Carl Bosch.

To produce ammonia, the hydrogen is catalytically reacted with

nitrogen (derived from process air) to form anhydrous liquid
ammonia. This step is known as the ammonia synthesis loop (also
referred to as the Haber-Bosch process):

Materials, H2+N2 Product, NH3

Haber-Bosch
Process
Some properties of ammonia
• Colorless gas with a characteristic pungent
smell similar to human urine, as urine
decomposes to release ammonia.
• Lighter than air, with density being 0.589
times that of air.
• Boils at -33.3 °C, and solidifies at -77.7 °C
to a mass of white crystals.
 EXAMPLE- AMMONIA PRODUCTION

Nitric Acid production

4 NH3 + 5O2 → 4 NO + 6 H2O
2 NO + O2 → 2 NO2
2 NO2 + 2 H2O → 2 HNO3 + H2

The catalyst is essential, as the normal oxidation (or

combustion) of ammonia gives nitrogen dioxide and water:
This nitrogen dioxide is reacted with water to produce nitric
acid for use in the production of fertilizer and explosives.
 EXAMPLE- AMMONIA USAGE

Fertilizer
As fertilizer ingredient

Refrigeration
Ammonia's thermodynamic properties made it one of the refrigerants commonly
used in refrigeration units prior to the discovery of Freon or R12 in 1928.

Disinfectant
It is also sometimes added to drinking water along with chlorine to form
chloramine, a disinfectant.

Fuel
Ammonia was used during World War II fuel shortages to power buses in Belgium
and used in engine and solar energy applications prior to 1900.

Cigarettes
During the 1960s, tobacco companies such as Brown & Williamson and Philip
Morris began using ammonia in cigarettes. Many hypotheses have appeared in the
media and technical literature that ammonia enhances the amount of nicotine
available to the smoker, nicotine's bioavailability, and the reinforcing or addictive
 EXAMPLE- AMINE SWEETENING

Chemical engineers also involved with pioneering valuable materials,

techniques and fields like nanotechnology, fuel cells and bioengineering.

19
BLOCK FLOW DIAGRAM

20
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

A plant consists of several process units such as

distillation column, reactor, preheater, tank and etc.

These process units are connected with pipelines and

becomes a continuous flow of reactants to products.

The plant can be represented by a Process Flow

Diagram (PFD)- showing the detailed flow of the
processes as well as Process and Instrumentation
Diagram (P&ID)-with the control strategy and
mechanism.

Each process flow in the PFD is represented by a

drawing symbol which is obtained from British
Standard or PETRONAS Standard.
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

Product
Tank 2
PROCESS AND INSTRUMENTATION DIAGRAM

Process and Instrumentation Diagram (P&ID)

 PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

Typical content of a process flow diagram:

• Process piping
• Major equipment items
• Control valves and other major valves
• Connections with other systems
• Major bypass and recirculation streams
• Operational data (temperature, pressure, mass
flowrate, density, etc), mass balance
• Process stream names
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

25
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

26
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

27
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

28
PROCESS FLOW DIAGRAM FOR A CHEMICAL INDUSTRY

29
COMPARISON OF PFD & P&ID

30
 DEFINATION OF CHEMICAL ENGINEER

A chemical engineer is the profession in which one works

principally in the chemical industry to convert basic raw materials
into a variety of products, and deals with the design and operation
of plants and equipment to perform such work.

In general, a chemical engineer is one who applies and uses

principles of chemical engineering in any of its various practical
applications; these often include:
i. design, manufacture, and operation of plants and machinery
in industrial chemical and related processes ("chemical
process engineers");
ii. development of new or adapted substances for products
ranging from foods and beverages to cosmetics to cleaners to
pharmaceutical ingredients
 CHEMICAL ENGINEER PROFESSION

Chemical engineer is also known as process engineer.

In reality, chemical engineer’s profession has gone

beyond the chemical industry, and at present
worldwide, they have the opportunities in a much
broader industries particularly in the oil, gas and
petrochemicals.

This is due to the much boarder knowledge that they

poses in fundamental sciences, mathematics,
engineering fundamentals, plant design & economic,
health safety & environment (HSE) and marketing.
 CHEMICAL ENGINEERS PROFESSION

Chemical engineers typically do the following:

• Conduct research to develop new and improved manufacturing
processes
• Develop safety procedures for those working with potentially
dangerous chemicals
• Develop processes to separate components of liquids and gases or
to generate electrical currents using controlled chemical processes
• Design and plan the layout of equipment
• Do tests and monitor performance of processes throughout
production
• Troubleshoot problems with manufacturing processes
• Evaluate equipment and processes to ensure compliance with
safety and environmental regulations
• Estimate production costs for management

Source: Chemical Engineering – https://www.truity.com/career-profile/chemical-engineer

Raw Materials Processes Products

34
 MAIN SUBJECT OF CHEMICAL
TECHNOLOGY

• Material and pre-treatment

• Routine of production
• Equipment and accessory
• Catalyst
• Effect of other material on the process
• Operating condition
• Process flow
• Separation and by-product
• Use of energy
• Evolution of technical economy

35
CHEMICAL ENGINEER PROFESSION
 CHEMICAL ENGINEER PROFESSION

• Chemical engineers on average are the highest paid of the

BIG FOUR (civil, mechanical, electrical, chemical). Many
chemical engineers have found their way to upper
management.
• A chemical engineer is either currently, or has previously,
occupied the CEO position for: 3M, Du Pont, General Electric,
Union Carbide, Dow Chemical, Exxon, BASF, Gulf Oil, Texaco,
and B.F. Goodrich. Even a former United States Secretary of
Energy from 2005-2009, Samuel W. Bodman, was a chemical
engineer by training. Dr Mukesh Ambani (Reliance Industries)
is also chemical engineer.
• Chemical engineers have been referred to as “universal
engineers”.

37
 CHEMICAL ENGINEER PROFESSION

Dr Margaret Hutchinson Rousseau

• Mass production of penicillin was a key moment in history.

• Margaret was the first women to receive a chemical
engineering doctorate from MIT.
• She also designed the first commercial penicillin plant.
Margaret developed the process of deep-tank fermentation
which enabled large-scale production of penicillin.

38
 CHEMICAL ENGINEER PROFESSION

Dr Waldo Semon

• American chemical engineer born on September 10, 1898.

• Invented tyres, PVC pipes.
• Invented PVC by mistake while trying to invent an adhesive
that stuck rubber to metal.
• He invented an indigestible synthetic rubber substance that
could be used as a bubble gum (and produced exceptionally
large bubbles).

39
 CHEMICAL ENGINEER PROFESSION
• Chemical engineers are not chemistry experts. Their purpose
is to apply chemistry to PRACTICAL problems.
• Apart from chemistry, chemical engineers are trained in
economics, business practice, environmental factors and
ethics.
• Chemists are trained only in the theory of chemistry whereas
engineers implement chemical theory in everyday life to solve
problems.

40
 CHEMICAL ENGINEERS PROFESSION

What Kind of Job I Will Get After Obtaining My

Degree?
Chemical Engineers work in wide range of jobs. Traditional areas
include chemicals, petrochemicals, and petroleum, while emerging
areas include environmental applications and design, semiconductor
manufacturing, pharmaceuticals, pulp and paper, plastics, food
engineering, and others. Many Chemical Engineers have their own
consulting businesses, and many have gone on to law or medicine.
The management ranks of many major chemical, petroleum, and
engineering corporations are staffed with Chemical Engineers and
graduate degrees in Chemical Engineering open many job areas
including industrial research and academia.

For more information, visit the AIChE (American Institute of Chemical Engineers)
website in the careers section.
Quoted from The University of Tusla, USA website
 CHEMICAL ENGINEERS PROFESSION
Annual wage for chemical engineers in May 2012:
(a) Top 10% earned more than $154,840
(b) Median - $94,350
(c) Lowest 10% earned less than $58,830

A June 2013 salary survey by the American Institute of Chemical Engineers of

their members reported that graduates of bachelor’s degree programs in 2011
had a median yearly salary of $67,800.

In May 2012, the median annual wages for chemical engineers in

the top five industries is as below:
Petroleum and coal products manufacturing $105,310
Basic chemical manufacturing $99,510
Scientific research and development services $97,880
Resin, synthetic rubber, and artificial synthetic fibers
$94,810
and filaments manufacturing
Architectural, engineering, and related services $93,390
Source: Chemical Engineering – https://www.truity.com/career-profile/chemical-engineer
CHEMICAL ENGINEERS PROFESSION

Source: Society of Human

Resource Management
(SHRM)-
http://www.shrm.org
CHEMICAL ENGINEERS PROFESSION

Source: Society of Human

Resource Management
(SHRM)-
http://www.shrm.org
 CHEMICAL ENGINEERS PROFESSION

Chemical engineering science utilizes mass, momentum, and energy

transfer along with thermodynamics and chemical kinetics to analyze and
improve on these “unit operations.”

Unit operations: filtration, drying, distillation, crystallization, grinding,

sedimentation, combustion, catalysis, heat exchange, coating, and so on.

Chemical engineering accomplishments:

45
 CHEMICAL ENGINEERS PROFESSION

Capstone: Capstone:
Plant Design Plant Design 4

Field Visit, Adjunct Lecture & Y

Industry Exposure Industrial Internship E
Separation Process I & II, Reaction Eng,
A
Core discipline Process Plant Design, R
Process Safety & Loss Prevention etc. S
Computational Method, Structured
Engineering fundamentals Programming & Database System,
HSE, etc.

Sciences & Mathematics Physics, Maths, Chemistry

 CHEMICAL ENGINEERS PROFESSION

Type of Industry/Sector Company Names

• Oil & Gas- upstream & PETRONAS
downstream Shell
• Petrochemicals Schlumberger
• Chemical Industries Baker Hughes
• Oleochemical Malaysian Oxygen
• Semiconductor Tioxide
• Government Malay Sino
• Educators Intel
• Research and AMD
Development DOE
• Automotive Institute of Higher Learning
• Consultant PORIM
• Etc… Etc…
Types of roles 5 – 15 years after graduation

48
 CONCLUSION

You have understood the following:

✓ The different between Chemist & Chemical

Engineer

✓ Chemical Industry

✓ Career Path for Chemical Engineer