A multilayered view of chemical engineering Rafiqul Gani

A multi-layered view of chemical engineering Rafiqul Gani* CAPEC KT Consortium Department of Chemical & Biochemical Engineering Technical University of Denmark, DK-2800 Lyngby, Denmark *College of Control Science & Engineering Zhejiang University, Hangzhou 310027, China rag@kt. dtu. dk http: //www. pseforspeed. com/ Sustainable Product-Process Engineering, Evaluation & Design

What is chemical engineering? Chemical engineering is the application of science, mathematics and economics to the process of converting raw materials or chemicals into more sustainable forms. The terms economics & sustainability are very important here. Sustainability Energy Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 2

What chemical engineers do? Highlights • • • Work with unit operations for purposes of chemical synthesis and/or separation (chemical reaction, mass-, heat- and momentum- transfer operations) Apply physical laws of conservation of mass, energy and momentum Apply principles of thermodynamics, reaction kinetics and transport phenomena Solve problems – design & operate processes More than just process engineering – applies chemical knowledge to create better materials and products that are useful to our modern society Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 3

A multi-layered view of Ch. E: Core layer Core of chemical & biochemical engineering deals with conversion of raw materials to useful products; finding the optimal synthesis routes and operating the processes for their designed applications, and through the use of science, mathematics, economics, …. Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 4

Where did this get us? We are the master of the planet earth . . . . Nutrition Fertilizers Electronics Vitamins Fuel Pharmaceuticals Detergents Healthcare Colorants and coatings Clothing Communications, Entertainment Mobility Plastics Housing Positive contribution to the development of our society Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 5

Classification of the key products in Ch. E Commodities Molecules Microstructures Key Cost. Manufacturing Speed. Selection Function-Need Basis Unit Ops Chemistry Microstructure Risk Feedstock Discovery Science Traditional Ch. E: Convert resources to commodities? Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 6

The future is unclear! Risky feedstock Resources Ch. E Fight for survival! Adopted from Cussler (2011) Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 7

Classification of the key products in Ch. E Commodities Single Species Multi Species Key Cost. Manufacturing Speed. Selection Function-Need Basis Unit Ops Chemistry Microstructure Risk Feedstock Discovery Science Ch. E is extending to design of single species products Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 8

For single species products, “selection” is key 46 Kilos = $800 M Adopted from Cussler (2011) Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 9

Classification of the key products in Ch. E Commodities Single Species Multi Species Key Cost. Manufacturing Speed. Selection Function-Need Basis Unit Ops Chemistry Microstructure Risk Feedstock Discovery Science Ch. E is also extending to design of multi species products Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 10

For multi species products, ”need” is the key Jet-fuel blend Gasoline blend Scientifically specified Sustainable Product-Process Engineering, Evaluation & Design Liquid formulations & emulsions Consumer reactions Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 11

Role & scope of Ch. E 1. What is the role of Chemical & Biochemical Engineering in “commodity” industry vs. “new emerging” technologies? Value preservation vs. Value creation 2. What is the future scope for fundamental contributions in Chemical & Bio-Chemical Engineering ? Engineering vs. Science 3. What are the major real world challenges Globalization-Environment (energy, water, health, food) Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 12

A multi-layered view of Ch. E: Interface layer The core, however, needs to be supplemented by appropriate levels of science and engineering to find sustainable and innovative solutions. Sustainable and innovative solutions can be found through an appropriate mix of science-engineering Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 13

Current & future challenges Sustainability Issues: Current and future survival World population is expected to reach 11 billions by 2050 Increase in water, energy & commodities demand 6 -7 x 5 -6 x 3. 5 x Global GDP growth over next ~50 years (in constant dollars) Production capacity for most commodities (steel, chemicals, lumber, etc. ) Energy demand Increase Water demand Increase GHG emissions Sustainable Product-Process Engineering, Evaluation & Design 7 x Electricity demand Adopted from Siirola, PSE-2012 Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 14

Is our future sustainable? The challenge facing us Convert resources to products Use energy, water, …. Environmental Impacts (GWP, OD, HTTP, …) Produce waste Sustainable Product-Process Engineering, Evaluation & Design Only 25% converted; must be > 40% (Driolli 2007) Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 15

Our position as the master of planet earth? Not threatened but our survival maybe is threatened unless we do something! Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 16

A multi-layered view of Ch. E: Connecting layer Grand challenges-opportunities Sustainable solutions (water, energy, resources) Processing Routes (reaction; separation; mixing; heating-cooling; etc. ) Innovative solutions (process, product) Application (industrial development) Sustainable Product-Process Engineering, Evaluation & Design Society Products (needs) Raw Materials (resources) Engineering Science Education Operation/Design (production) The overall objectives are to serve the society through educating the necessary engineers who can apply their education-training for industrial development taking advantage of the opportunities available and addressing the challenges being faced Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 17

Click edit Master title style What to to make and how to make? Questions: what, why & when? Zhang, Babi & Gani, Annual Rev of Chem & Biomedical Eng, 2016 Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 18

Need for integrated multidisciplinary approach REALITY System under study Experiments Provide realistic model parameters Verify theoretical solutions Guidance and insights for experiments VIRTUAL REALITY Model system Sustainable Product-Process Engineering, Evaluation & Design Simulations • Solution approaches Optimized design? Integrated modeling, experiments and synthesis Ability to find predictive- innovative and more sustainable solutions Optimized design? Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 19

Can the current methods, tools technologies deliver? Well-known PSE tools: ASPEN, g. PROMS, HYSIS, PROII, Chem. Cad, …. (design, optimization, control, plan-schedule operations, …) Can our current methods and tools solve the problems of our interest? Or, do we need a new class of software tools that promote innovation? Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 20

Need for innovation in process-product design How to find new and significantly better unit operations? Methanol + Acetic Acid = Methyl Acetate + Water Eastman Chemicals Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 21

Development of Ch. E – new directions Unique opportunities and formidable challenges Probe the frontiers of technological innovations to bring • New categories of abundant resources • Substitute and/or improve resources that become scarce • Deliver sustainable solutions (energy, water, food …) • Contribute to staving off disasters (global climate change, a viral pandemic, oil spills, …) • 3 rd Paradigm (Integration of process-product-phenomena) Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 22

Necessary shift in education - 1 1. Need to keep core Chemical Engineering Knowledge; Need to emphasize fundamentals: basis is life-long learning 2. Need to modernize curriculum and add flexibility • Increase exposure at molecular level • Increase exposure to energy (alternative/renewable) and sustainability issues • Expose students to new process technology • Introduce product design as complement of process design • Emphasize process operations, enterprise planning • Increase link to other industrial sectors (pharma, electronics) Adopted from Grossmann 2014 Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 23

Necessary shift in education - 2 3. Need to recognize that “bio-area” & “nano-area” will be important but not dominant force in Chemical Engineering 4. Environmental Engineering increasingly important and requires chemical engineering (water use efficiency, pollution control, chemical substitution, …) : Civil Eng. ownership? 5. Need closer interaction with industry; otherwise risk being irrelevant 6. Need to provide excitement to recruit the very best young people to join Chemical Engineering Adopted from Grossmann 2014 Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 24

Are we now entering a golden age for Ch. E? Adopted from Phil Westmoreland’s* 5 reasons • Manufacturing’s shift to emphasize processes and properties (smart manufacturing) • New abundance of hydrocarbon resources in USA, China & other locations (a game changer) • Biology’s turning into a molecular science (multi-disciplinary) • Computing, evolved into a cyberinfrastructure (knowledge and data management – big data) • Ch. Es’ breadth and problem-solving approaches (contribute to the society) * President of the AICh. E, 2013 Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 25

Conclusions & future directions Ch. E’s positive contribution to the modern society through P 3 I • Need to adapt to the needs of the modern society (questions of energy, water, environment, sustainability, responsibility, . . . should be incorporated in the study) • Courses need to adopt (introduction of new ideas, new methods, new tools, . . ) • Balance between engineering-science; commodity-value added; core-new need to be found (different solutions are possible) Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 26

Conclusions & future directions Barcelona Declaration, 2017 An increasing world population, in a world of finite natural resources, requires ever more innovative engineering to solve problems and produce new and better products with a negligible environmental footprint. Chemical engineering and related sciences and technologies must play a key role in meeting future societal needs. We, as chemical and biochemical engineers, need to renew our commitment to use our skills to improve the quality of life, foster employment, advance economic and social development and protect the planet through sustainable development. Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 27

Conclusions & future directions We should agree to: Barcelona Declaration, 2017 • Promote research and development as a fundamental pillar and encourage technology development to achieve a planet able to sustain a growing population, while improving quality of life. • Facilitate global dissemination of chemical and biochemical engineering technical knowledge and industrial best practices, striving to bring together academia and industry worldwide. • Promote conservation and care of global resources, health, safety, and the environment. • Promote the highest standards of professional ethics and conduct for chemical engineers worldwide, to safeguard the public. Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 28

Ch. E is a problem solver not a problem creator! Chemical engineer If I change one molecule of this useless & polluting product, we can make an excellent hair-spray! Sustainable Product-Process Engineering, Evaluation & Design Rafiqul Gani, ICFMCE 2017, Dubai, 24 -26 November 2017 29