Chemical engineering is an engineering field which deals with the study of operation and design of chemical plants as well as methods of improving production. Chemical engineers develop economical commercial processes to convert raw material into useful products. Chemical engineering uses principles of chemistry, physics, mathematics, biology, and economics to efficiently use, produce, design, transport and transform energy and materials. The work of chemical engineers can range from the utilization of nanotechnology and nanomaterials in the laboratory to large-scale industrial processes that convert chemicals, raw materials, living cells, microorganisms, and energy into useful forms and products. Chemical engineers are involved in many aspects of plant design and operation, including safety and hazard assessments, process design and analysis, modeling, control engineering, chemical reaction engineering, nuclear engineering, biological engineering, construction specification, and operating instructions.
Process engineering is the understanding and application of the fundamental principles and laws of nature that allow humans to transform raw material and energy into products that are useful to society, at an industrial level. By taking advantage of the driving forces of nature such as pressure, temperature and concentration gradients, as well as the law of conservation of mass, process engineers can develop methods to synthesize and purify large quantities of desired chemical products. Process engineering focuses on the design, operation, control, optimization and intensification of chemical, physical, and biological processes. Process engineering encompasses a vast range of industries, such as agriculture, automotive, biotechnical, chemical, food, material development, mining, nuclear, petrochemical, pharmaceutical, and software development. The application of systematic computer-based methods to process engineering is "process systems engineering".
Biochemical engineering, also known as bioprocess engineering, is a field of study with roots stemming from chemical engineering and biological engineering. It mainly deals with the design, construction, and advancement of unit processes that involve biological organisms or organic molecules and has various applications in areas of interest such as biofuels, food, pharmaceuticals, biotechnology, and water treatment processes. The role of a biochemical engineer is to take findings developed by biologists and chemists in a laboratory and translate that to a large-scale manufacturing process.
A microreactor or microstructured reactor or microchannel reactor is a device in which chemical reactions take place in a confinement with typical lateral dimensions below 1 mm; the most typical form of such confinement are microchannels. Microreactors are studied in the field of micro process engineering, together with other devices in which physical processes occur. The microreactor is usually a continuous flow reactor. Microreactors offer many advantages over conventional scale reactors, including vast improvements in energy efficiency, reaction speed and yield, safety, reliability, scalability, on-site/on-demand production, and a much finer degree of process control.
The Fischer–Tropsch process is a collection of chemical reactions that converts a mixture of carbon monoxide and hydrogen or water gas into liquid hydrocarbons. These reactions occur in the presence of metal catalysts, typically at temperatures of 150–300 °C (302–572 °F) and pressures of one to several tens of atmospheres. The process was first developed by Franz Fischer and Hans Tropsch at the Kaiser-Wilhelm-Institut für Kohlenforschung in Mülheim an der Ruhr, Germany, in 1925.
A chemical plant is an industrial process plant that manufactures chemicals, usually on a large scale. The general objective of a chemical plant is to create new material wealth via the chemical or biological transformation and or separation of materials. Chemical plants use specialized equipment, units, and technology in the manufacturing process. Other kinds of plants, such as polymer, pharmaceutical, food, and some beverage production facilities, power plants, oil refineries or other refineries, natural gas processing and biochemical plants, water and wastewater treatment, and pollution control equipment use many technologies that have similarities to chemical plant technology such as fluid systems and chemical reactor systems. Some would consider an oil refinery or a pharmaceutical or polymer manufacturer to be effectively a chemical plant.
Coal liquefaction is a process of converting coal into liquid hydrocarbons: liquid fuels and petrochemicals. This process is often known as "Coal to X" or "Carbon to X", where X can be many different hydrocarbon-based products. However, the most common process chain is "Coal to Liquid Fuels" (CTL).
Sonication is the act of applying sound energy to agitate particles in a sample, for various purposes such as the extraction of multiple compounds from plants, microalgae and seaweeds. Ultrasonic frequencies (> 20 kHz) are usually used, leading to the process also being known as ultrasonication or ultra-sonication.
Fine chemicals are complex, single, pure chemical substances, produced in limited quantities in multipurpose plants by multistep batch chemical or biotechnological processes. They are described by exacting specifications, used for further processing within the chemical industry and sold for more than $10/kg. The class of fine chemicals is subdivided either on the basis of the added value, or the type of business transaction, namely standard or exclusive products.
In flow chemistry, a chemical reaction is run in a continuously flowing stream rather than in batch production. In other words, pumps move fluid into a reactor, and where tubes join one another, the fluids contact one another. If these fluids are reactive, a reaction takes place. Flow chemistry is a well-established technique for use at a large scale when manufacturing large quantities of a given material. However, the term has only been coined recently for its application on a laboratory scale by chemists and describes small pilot plants, and lab-scale continuous plants. Often, microreactors are used.
A fluidized bed reactor (FBR) is a type of reactor device that can be used to carry out a variety of multiphase chemical reactions. In this type of reactor, a fluid is passed through a solid granular material at high enough speeds to suspend the solid and cause it to behave as though it were a fluid. This process, known as fluidization, imparts many important advantages to an FBR. As a result, FBRs are used for many industrial applications.
The Indian Institute of Petroleum (IIP), established in 1960, is one of the constituent laboratories of the Council of Scientific and Industrial Research (CSIR), dedicated to R&D in the hydrocarbon sector.
Verification and validation are independent procedures that are used together for checking that a product, service, or system meets requirements and specifications and that it fulfills its intended purpose. These are critical components of a quality management system such as ISO 9000. The words "verification" and "validation" are sometimes preceded with "independent", indicating that the verification and validation is to be performed by a disinterested third party. "Independent verification and validation" can be abbreviated as "IV&V".
Process simulation is used for the design, development, analysis, and optimization of technical processes such as: chemical plants, chemical processes, environmental systems, power stations, complex manufacturing operations, biological processes, and similar technical functions.
An alkylation unit (alky) is one of the conversion processes used in petroleum refineries. It is used to convert isobutane and low-molecular-weight alkenes (primarily a mixture of propene and butene) into alkylate, a high octane gasoline component. The process occurs in the presence of an acid such as sulfuric acid (H2SO4) or hydrofluoric acid (HF) as catalyst. Depending on the acid used, the unit is called a sulfuric acid alkylation unit (SAAU) or hydrofluoric acid alkylation unit (HFAU). In short, the alky produces a high-quality gasoline blending stock by combining two shorter hydrocarbon molecules into one longer chain gasoline-range molecule by mixing isobutane with a light olefin such as propylene or butylene from the refinery's fluid catalytic cracking unit (FCCU) in the presence of an acid catalyst.
Syngas to gasoline plus (STG+) is a thermochemical process to convert natural gas, other gaseous hydrocarbons or gasified biomass into drop-in fuels, such as gasoline, diesel fuel or jet fuel, and organic solvents.
Process chemistry is the arm of pharmaceutical chemistry concerned with the development and optimization of a synthetic scheme and pilot plant procedure to manufacture compounds for the drug development phase. Process chemistry is distinguished from medicinal chemistry, which is the arm of pharmaceutical chemistry tasked with designing and synthesizing molecules on small scale in the early drug discovery phase.
The scale of a chemical process refers to the rough ranges in mass or volume of a chemical reaction or process that define the appropriate category of chemical apparatus and equipment required to accomplish it, and the concepts, priorities, and economies that operate at each. While the specific terms used—and limits of mass or volume that apply to them—can vary between specific industries, the concepts are used broadly across industry and the fundamental scientific fields that support them. Use of the term "scale" is unrelated to the concept of weighing; rather it is related to cognate terms in mathematics, and in applied areas.
A demonstration plant is an industrial system used to validate an industrial process for commercialization. It is larger than a pilot plant, and is the final stage in research, development and demonstration of a new process. Demonstration plants are built in a range of sizes, and the term 'demonstration plant' can sometimes be used interchangeably with 'pilot plant.' However, demonstration plants are generally larger than pilot plants, and are often constructed following a successful trial in a pilot scale size. Demonstration plants are used to prove a process works at industrial scale, and is financially viable in its intended industry.
Aspen Plus, Aspen HYSYS, ChemCad and MATLAB, PRO are the commonly used process simulators for modeling, simulation and optimization of a distillation process in the chemical industries. Distillation is the technique of preferential separation of the more volatile components from the less volatile ones in a feed followed by condensation. The vapor produced is richer in the more volatile components. The distribution of the component in the two phase is governed by the vapour-liquid equilibrium relationship. In practice, distillation may be carried out by either two principal methods. The first method is based on the production of vapor boiling the liquid mixture to be separated and condensing the vapors without allowing any liquid to return to the still. There is no reflux. The second method is based on the return of part of the condensate to still under such conditions that this returning liquid is brought into intimate contact with the vapors on their way to condenser.
