The Role of the Design Engineer in Technology Development 3/21/13 Auburn University Robert Kline

What is a Design Engineer? An engineer whose primary focus is the design of chemical processes, equipment, or other detail needed in order to build a chemical plant. An engineer whose primary focus is the design of chemical processes, equipment, or other detail needed in order to build a chemical plant. What isn’t a Design Engineer What isn’t a Design Engineer Operation/Manufacturing Support Operation/Manufacturing Support Technical Service Technical Service Laboratory/Pilot Plant Engineering Laboratory/Pilot Plant Engineering Other (sales, training, HR) Other (sales, training, HR)

Chemical Project Phases Discovery Discovery Technology Development Technology Development Project Implementation Project Implementation Start-Up Start-Up Continued Operation Continued Operation

Discovery Goal Goal To find a way to make chemical X, Or To find a way to make chemical X, Or To use chemistry Y to make something new To use chemistry Y to make something new Activities Activities Literature Review Literature Review Route/Chemical Comparison & Selection Route/Chemical Comparison & Selection Preliminary Lab Scale Experiments Preliminary Lab Scale Experiments Initial Economic Evaluation (In/Out analysis) Initial Economic Evaluation (In/Out analysis)

Technology Development Goal Goal To figure out how to most economically use the discovery To figure out how to most economically use the discovery Activities Activities Directed Experiments (kinetics, efficiencies, etc) Directed Experiments (kinetics, efficiencies, etc) Flowsheet Determination Flowsheet Determination Catalyst & Solvent Selection Catalyst & Solvent Selection High Level Process Optimization High Level Process Optimization Piloting Piloting Preliminary Sizing & Cost Estimation Preliminary Sizing & Cost Estimation Early Basic Engineering Early Basic Engineering

Project Implementation Goal Goal To further design and then implement the technology To further design and then implement the technology Activities Activities Front End or Basic Engineering Design Front End or Basic Engineering Design Figuring out what the process and equipment look like Figuring out what the process and equipment look like Detailed material and energy balances, equipment specifications, preliminary P&IDs, and control strategies Detailed material and energy balances, equipment specifications, preliminary P&IDs, and control strategies Detailed Engineering & Procurement Detailed Engineering & Procurement Figuring out what you need to buy Figuring out what you need to buy Final layouts and P&IDs Final layouts and P&IDs Construction Construction Making sure you get what you need in the right place Making sure you get what you need in the right place

Start Up Goal Goal Produce on spec product at close to design rates Produce on spec product at close to design rates Activities Activities Troubleshoot real problems Troubleshoot real problems Identify false problems Identify false problems Rework off class material Rework off class material Understand the difference between design and reality Understand the difference between design and reality

Continued Operation Goal Goal Meet production demands for low conversion cost Meet production demands for low conversion cost Activities Activities Daily operation management Daily operation management Analysis and reduction of costs Analysis and reduction of costs Environmental & safety compliance Environmental & safety compliance

Cost Impact by Project Stage

Technology Development Tasks (1) Understand the Technology Understand the Technology Talk with lab chemists and technology experts and manage information interfaces Talk with lab chemists and technology experts and manage information interfaces Understand the intrinsic behavior of each subsystem (Unit Operation view) Understand the intrinsic behavior of each subsystem (Unit Operation view) Know why each operation behaves as it does and what could interfere with it Know why each operation behaves as it does and what could interfere with it Direct experiments to expand and validate behavior models and understanding Direct experiments to expand and validate behavior models and understanding

Technology Development Tasks (2) Choose a Process Choose a Process Know the benefits of each system/subprocess Know the benefits of each system/subprocess Determine preliminary connections of the subprocesses Determine preliminary connections of the subprocesses Understand what is needed for the process to work (Feasibility) Understand what is needed for the process to work (Feasibility) Understand how the needs can be satisfied in the lowest cost manner (Cost effectiveness) Understand how the needs can be satisfied in the lowest cost manner (Cost effectiveness) Weigh risks of process complexity vs cost advantage Weigh risks of process complexity vs cost advantage

Technology Development Tasks (3) Optimize the System Optimize the System See how the parts fit together and impact one another (Process view) See how the parts fit together and impact one another (Process view) Understand tradeoffs & costs Understand tradeoffs & costs Verify that the identified technology needs are valid and can be satisfied Verify that the identified technology needs are valid and can be satisfied Identify what is important and what isn't Identify what is important and what isn't

Technology Development Decision Example #1 Process Reactor Product Column Catalyst Column Feeds Water Product Reactor Product Column Catalyst Extractor Feeds Water Product Solvent Column Solvent Catalyst Which water removal process should you choose? What should you consider? Which water removal process should you choose? What should you consider?

Technology Development Decision Example #2 Catalyst For a new project initial lab results show that a homogenous catalyst has rates an order of magnitude higher that the original heterogeneous catalyst. Should you switch? What should you consider? For a new project initial lab results show that a homogenous catalyst has rates an order of magnitude higher that the original heterogeneous catalyst. Should you switch? What should you consider? A pilot plant is already being constructed. How does that change the decision? A pilot plant is already being constructed. How does that change the decision?

Technology Development Decision Example #3 Reaction A + B  C (desired product) A + B  C (desired product) C  D (byproduct) C  D (byproduct) Is it worth putting in a system to convert D back to C? Is it worth putting in a system to convert D back to C?