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Chemical Engineering
Summer@Brown
2011
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August 28, 1859 - Titusville, Pennsylvania
Edwin Drake
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Haifa, Israel
9 million tons (66 million barrels) of crude oil/ year
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What is Chemical Engineering?
Basic sciences PLUS engineering fundamentals:
Convert raw materials into valuable products
Design and manufacture devices
This is accomplished by:
Chemical reactions (making and breaking of bonds)
Catalysis (accelerating chemical reactions)
Separation, purification of complex chemical mixtures
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Famous Chemical Engineers
Linus PaulingNobel Prize in Chemistry, 1954,
Nobel Peace Prize, 1962
Jack WelchFormer CEO of General Electric
Lee RaymondExxonMobile chairman and CEO
Victor MillsInvented first disposable diaper
Robert GoreInventor of Gore-Tex
Samuel BodemanFormer United States
Secretary of Energy (2005-2009)
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Convert Raw Materials into Valuable
Products
Crude OilGasoline, Jet Fuel, Monomers
MonomersPolymers (ethylene
polyethylene) Silicon crystalsSemiconductors, integrated
circuits
Inorganic PrecursorsCeramics Corn StarchHigh Fructose Corn Syrup
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Design and Manufacture Devices
Chemical plants (paper, plastics, fertilizers)
Electronics
Biomedical devices (artificial kidney, hearts)
Diagnostic/Drug delivery devices
Novel materials (polymers, fibers, ceramic)
Energy devices (batteries, fuel cells)
Waste treatment solutions
Specialty chemicals (foods, flavors, fragrances)
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Chemist vs. Chemical Engineer
Chemists:Design new molecules and
synthesizes new formulas
Work in grams of materials
Chemical Engineers: Design equipment and
processes for large-scale chemical
manufacturing
Work in tonnesof materials
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Bhopal Gas Tragedy
Union Carbide India Limited pesticide plant,
Bhopal, India - December 2-3, 1984
1-naphthol chloroformate carbaryl
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Factors leading to the Bhopal disaster
Caused >15,000 deaths
Use of hazardous chemicals (MIC) instead of less dangerousones
Storing these chemicals in large tanks instead of over 200steel drums.
Possible corroding material in pipelines Poor maintenance after the plant ceased production in the
early 1980s
Failure of several safety systems (due to poor maintenanceand regulations).
Safety systems being switched off to save moneyincluding the MIC tank refrigeration system
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A Chemical Engineers Curriculum
Lots of Math, Chemistry and Physics
Fundamental Classes Heat and Mass Transfer
Chemical Thermodynamics Chemical Kinetics
Fluid Mechanics
Units of Chemical Processes: chemical reactors,bioreactors, distillation columns, heat exchangers
Design Chemical Processintegrate process unitswith regard to economics, safety and environmentalimpact
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Job Opportunities
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The Fundamentals
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Black Box Theory
Device, system or object which can be viewed solely interms of its input, output and transfer characteristicswithout any knowledge of its inner workings
Examples:
Computer programming; software testing
Finance: market prediction
Climate change- weather prediction
Physics: Particle physics Hadron Collider
Human mind: fMRI Biological systems
Black box theory has been used in many fields ofscience and engineering
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Refinery Operations
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Evaporator
Converts Liquid -> Gas
Heat Exchanger
A(75C)A(30C)
Distillation Column
ABA + B
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Process
Unit
Input/Feed Output
DistillationABA + B
Heat Exchanger
A(75C)
A(30C)
Blackbox
Unit
Operations
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Process streams
Mass flow rate, m,
(kg/h)
Volumetric flow rate, V
(L/min)
.
.m
mass
time
.
Vvolume
time
. m V. .
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Process
Unit
Input/Feed Output
DistillationABA + B
Heat Exchanger
A(75C)
A(30C)
Blackbox
Unit
Operations
m1, v1
. .
m2, v2
. .
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The volumetric flow rate of CCl4 (= 1.595 g/cm3) in a
pipe is 100.0 cm3/min. What is the mass flow rate of
the CCl4?
Question 1
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Process
Unit
Input/Feed Output
Min (kg CH4/h).
Mout (kg CH4/h).
Min!= Mout. .
Why?
1. Incorrect measurement2. Leakage
3. Adsorption onto the walls
4. Reacted away? Or generated as a product?
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Conservation of Mass
What goes in must come out!!
At steady state, accumulation in system = 0:
No reaction:
Input + Generation - Output - Consumption = Accumulatio
Input - Output = 0
Input + Generation - Output - Consumption = 0
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Each year 50,000 people move into a city, 75,000
people move out, 22,000 are born and 19,000 die.
Write a balance on the population of the city.
Question 2
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A feed stream of pure liquid water enters an evaporator ata rate of 0.5 kg/s. Three streams come from theevaporator: a vapor stream and two liquid streams. Theflow-rate of the vapor stream was measured to be 4 X 106
L/min and its density was 0.004 kg/m3. The vapor streamenters a turbine, where it loses enough energy to condensefully and leave as a single stream. One of the liquid streamsis discharged as waste, the other is fed into a heat
exchanger, where it is cooled. This stream leaves the heatexchanger at a rate of 0.1893 kg/s. Calculate the flow rateof the discharge and the efficiency of the evaporator.
Question 3
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One thousand kilograms per hour of a mixture of
benzene (B) and toluene (T) containing 50%
benzene by mass is separated by distillation into two
fractions. The mass flow rate of benzene in the topstream is 450 kg B/h and that of toluene in the
bottom stream is 475 kg T/h. The operation is at
steady state. Write balances on benzene andtoluene to calculate the unknown component flow
rates in the output streams.
Question 4
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Question 5
Two methanol-water mixtures are contained in separate
flasks. The first mixture contains 40.0 wt% methanol, and the
second contains 70.0 wt% methanol. If 200 g of the first
mixture is combined with 150 g of the second, what are themass (m) and composition of the product?
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Case Study:
High Fructose Corn Syrup
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High Fructose Corn Syrup
Milestones
1957Process developed by Richard O. Marshall
and Earl R. Kooi
Up until 1970: sucrose used as a main sweetener
19751985HFCS introduced to processed
foods and soft drinks
Common forms: HFCS 42 and HFCS 55
Soft Drinks 95%
Baked Goods 25%
Diary 30%
Processed Foods 45%
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Sold in a bushel: 56 pounds of wet corn
(48.1 lb of dry corn + 7.9 lb of water)
Milling Process
Corn Oil 1.6 lb
Cornmeal 2.5 lb
Animal Feed 12.5lb
Starch 31.5 lb
Water 7.9 lb
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Extract Weight/Bushel Cost/Pound Cost/Bushel
Corn Oil 1.6 lb $0.27/lb $0.43/bushel
Cornmeal 2.5 lb $0.132/lb $0.33/bushel
Animal Feed 12.5 lb $0.044/lb $0.55/bushel
Starch 31.5 lb ? ?
Water 7.9 lb --- ----
$1.31/bushel
Raw Material Weight/Bushel Cost/Pound Cost/Bushel
Wet Corn 56 lb $0.047/lb $2.63/bushel
Cost Analysis of Harvesting Corn
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Corn Starch High Fructose
Corn Syrup
Liquefication
G-G-G-G-G-G G, G-G, G-G-G
Saccharification
G-G, G-G-G G, G, G, G, G
Isomerization Glucose Fructose
-amylase
Glucoamylase
Glucose isomerase
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Corn Starch
Other ExtractsStarch Purification
Liquefaction
Saccharification
Isomerization
Separator
55% HFCS42% HFCS
-amylase
plant
glucoamylase
plant
glucoisomerase
plant
3 hrs, pH 6-7, Initial: 300F, 30
min, Heat: 185F, 30 min, Cool:
140F, 30 min
40-90 hours, pH 4, 140F
30 min process, pH
7, 140-150F
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Composition % Fructose % Glucose % Solid
HFCS 42 42 58 70
HFCS 55 55 45 70
Raw Material Weight/Bushel Cost/lb Cost/Bushel
HFCS 42 31.5 lb $0.18/lb $5.67
HFCS 55 31.5 lb $0.20/ lb $6.30
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Extract Weight/Bushel Cost/Pound Cost/Bushel
Corn Oil 1.6 lb $0.27/lb $0.43/bushel
Cornmeal 2.5 lb $0.132/lb $0.33/bushel
Animal Feed 12.5 lb $0.044/lb $0.55/bushel
Starch 31.5 lb $0.18/lb $5.67/bushel
Water 7.9 lb --- ----
$7.42/bushel
Raw Material Weight/Bushel Cost/Pound Cost/Bushel
Wet Corn 56 lb $0.047/lb $2.63/bushel
Cost Analysis of Harvesting Corn
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Operation Research and
Industrial EngineeringORIE, IEOR, OR-SE-IE
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Originated in military efforts in WWII
Evaluates efficacy of the use of technology
Decision science: OR finds optimal solutions to
complex decision making process
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Examples
1. Routing: Routes of buses so few buses are needed2. Floor-planning: layout of equipment of factory or
computer chip to reduce manufacturing time/ costs
3. Network optimization: set-up of telecommunicationsnetwork to maintain quality of service during
outages
4. Healthcare: How effective are various disease
treatments
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Courses?
Statistics
Optimization
Probability theory
Decision analysis
Queuing/Game/Graph theories
Computer science/analytics
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Financial Engineering
NOT a real engineering discipline!
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Applies engineering methodologies to
problems in finance
Combines:
to predict
Design new financial instruments Models to help minimize financial risk
Math + Finance + Computer Modellin
Pricing + Hedging + Trading
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Jobs?
Investment banks
Securities industry
Consulting firms (quantitative analysts)
Corporate finance/risk management roles in
other general manufacturing and service firms
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Prerequisite: Bachelors incomputer science,
operation research
economics or math Master of Financial
Engineering
Master of QuantitativeFinance
PhDs in computer science
or applied mathematics
Face of a Financial Engineer?
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