1. Cairo University Faculty of Engineering Chemical Engineering Department Introduction to Chemical Engineering Chapter 1 INTRODUCTION October 2009

2. contents 1.General 2.What is a chemical engineer ? 3. What is special about chemical engineers? 4. Chemical engineers ten Greatest Achievements 5. Where you will get a job ? 6.Summary 7.Course outline

3. 1. General Chemical engineering is one of the big four branches of engineering: civil, mechanical, electrical and chemical Chemical engineering is well established in Egypt ( see next slide ) Chemical engineers are very well recognized in North America and Europe

4. Chemical Engineering Departments in Egypt Cairo University1942 Alexandria University1946 Menya University 1978 Military Technical College 1962 10 th of Ramadan Technical Institute 1990 Al Sherook Academy 1998

5. 2. What is a chemical engineer? We will answer the question after presnting two illustrative examples

6. Illustrative example 1 A chemist working in the research and development (R&D) department in a pharmaceutical company discovered a process for producing a new valuable substance C. The reaction he applied is as follows: A + B  C + unreacted A + unreacted B The work of the chemist in the Lab may be illustrated as follows:

8. Lab Glassware

9. InputsProcessOutputs 10ml A 10ml B Reaction 70 o C Heat Energy Cooling Filtration Drying Warm tap water (Filtrate) Unreacted A + B Vapors Product C 19 m / batch Heat energy Cold tap water Solid C

10. InputsDescription of Work in the LabOutputs 10ml A 10ml B Heat energy Tap water for Cooling Filteration Drying Substance C Filtrated to Sink Product D one gram Tap water to sink Precipitated C Glass rod for mixing

11. From laboratory scale to industrial scale After a lot of discussions and studies (?), the company decided to build a plant to produce substance C with a production capacity of 1 ton/day. lab scale: 1 gm/day industrial scale: 1,000,000 gm/day scale up factor: 1,000,000

12. In the lab, a glass beaker is used as a reactor

13. Industrial reactor

14. Industrial size Chemical Reactor

15. Storage of raw materials Liquid storage tank

18. Industrial dryer Steam-tube rotary dryer

20. 3. What is special about chemical engineers?

21. Chemical engineers master the process design required for the production of materials we use in our daily life. They are involved in all phases of technology development: IDEA APPLICATION of SCIENCE MANUFACTURE Physical, chemical, biological & engineering science Economics, business, management science Chemical engineers are described as the “universal engineer” because they have a broad knowledge of:

22. Chemical engineers design, test, scale-up, operate, control, and optimize "unit operations“ of a process, such as distillation, mixing, and reactions. Only chemical engineers use chemistry along with mathematics, physics, biology to solve technical problems in a safe and economical fashion. Chemical engineering science uses mass, momentum, and energy transfer along with thermodynamics and chemical kinetics to analyze processes and improve them. Only chemical engineers develop chemical and biochemical processes that turn raw materials into valuable products.

23. 4. Chemical engineers ten Greatest Achievements 1.Splitting of the atom and isolating isotopes. 2. Mass production of cheap plastic. 3. The development of the "Unit Operations" of the human reactor 4. Low price, high volume production of wonder drugs for the masses. 5. Synthetic fibers. 6. Liquefied air and its separation into pure constituents. 7. Environmentally conscious engineering 8. Chemical fertilizers, food processing, Biotechnology of food production. 9. Petroleum processing 10. Synthetic Rubber.

24. 5. Where you will get a job ?

25. Products and Processes Consumer Products Food, water, clothing, medicines, health & beauty aids, fuels, lubricants Commodity Chemicals Oxygen, water, sulfuric acid, ammonia, chlorine, lye (soap), ethylene oxide, plastics, rubber Electronic/Optical Matls. High purity silicon, compound semiconductors, thin films, optical polymers Special materials Biomaterials (prostheses), Nylon, Kevlar, Teflon Processes Large scale chemical plants continuous processes that make commodity chemicals at low cost ($100–500 million) Intermediate scale plants for specialty chemicals ($10–100 million) Small scale batch processes for biomaterials and bioengineering ($1–10 million)

29. SOME SUB-CATAGORIES: Pharmaceutical Engineering Plastics and Polymer Engineering Petroleum Engineering… Chemical engineers provide the skills needed to develop new polymers for medical devices, powerful new alloys for aircraft, components for the development of computer and other electronics industries. Health care will require new manufacturing processes for pharmaceutical products and surgical procedures. Chemical engineers are in many industrial sectors

30. Bachelor'sMaster'sDoctor's Chemical Engineering$46,900$52,100$67,300 Electrical Engineering$45,200$57,200$70,800 Mechanical Engineering$43,300$51,900$64,300 Civil Engineering$36,100$42,300$58,600 Source: "National Association of Colleges and Employers, 1999 Survey" Note that BS chemical engineers are loosing their salary advantage USA data: 1999 Entry Level Wages Based on Degree Earned Bachelor'sMaster'sDoctor's Chemistry$29,500$38,500$59,300 Source: "ACS Survey of recent graduates, 1998" USA data: 1998 Entry Level Wages Based on Degree Earned http://www.aiche.org/careerservices/library/pdf/salary080202.pdf Please read this article:

31. 6. Summary Chemical engineering is the application of science, mathematics and economics to the process of converting raw materials or chemicals into more useful or valuable forms.engineering sciencemathematicseconomicsmaterialschemicals Chemical Engineering largely involves the design and maintenance of chemical processes for large- scale manufacture. Chemical engineers in this branch are usually employed under the title of process engineer.

32. (Cnt’d) Summary The individual processes used by chemical engineers (eg. distillation or chlorination) are called unit operations and consist of chemical reaction, mass-, heat- and momentum- transfer operations. Unit operations are grouped together in various configurations for the purpose of chemical synthesis and/or chemical separation.distillationchlorinationunit operations chemical reactionmass-heat- momentum-chemical synthesischemical separation

33. (cont’d) Summary Three primary physical laws underlying chemical engineering design are Conservation of mass, Conservation of momentum and Conservation of energy. The movement of mass and energy around a chemical process are evaluated using Mass balances and energy balances which apply these laws to whole plants or a single unit operation.Conservation of mass Conservation of momentumConservation of energyMass balances In doing so, Chemical Engineers use principles of thermodynamics, reaction kinetics and transport phenomena. thermodynamicsreaction kineticstransport phenomena

34. (cont’d) Summary Chemical engineers are now engaged in the development and production of a wide range of products, as well as in commodity and specialty chemicals. These products include high performance materials needed for aerospace, automotive, biomedical, electronic, environmental and military applications. Examples include ultra-strong fibers, fabrics, adhesives and composites for vehicles, bio- compatible materials for implants and prosthetics, gels for medical applications, pharmaceuticals, and films with special dielectric, optical or spectroscopic properties for opto-electronic devices. Additionally, chemical engineering is often intertwined with biology and biomedical engineering.chemicalsaerospace automotivebiomedicalelectronicenvironmental military fabricsadhesivesbio- compatible materialsgelspharmaceuticalsspectroscopicbiology biomedical engineering

35. 7. Course Outline 1.Introduction 2.History and basic concepts 3.Product design 4.Process design 5.Plant design 6.The sugar industry 7.The petrochemical industry

36. (Contd.) Course Outline 8. Energy, fuels and environmental problems 9. Biotechnology 10. Biomedical engineering applications 11. Cleaner production 12. Overview of the chemical process industry: past, present and future