Wednesday, August 17, 2011
Tuesday, March 29, 2011
Tip #23 For Better Chemical Engineering: Laboratory fractionating columns
A laboratory fractionating column is a piece of glassware used to separate vaporized mixtures of liquid compounds with close volatilities. It can also be called a fractional column. Most commonly used is either a Vigreux column or a straight column packed with glass beads or metal pieces such as Raschig rings.
Image 1: Fractional distillation apparatus using a Liebig condenser
Fractionating columns help to separate the mixture by allowing the mixed vapors to cool, condense, and vaporize again in accordance with Raoult's law. With each condensation-vaporization cycle, the vapors are enriched in a certain component. A larger surface area allows more cycles, improving separation. This is the rationale for a Vigreux fractionating column or a packed fractionating column. Spinning band distillation achieves the same outcome by using a rotating band within the column to force the rising vapors and descending condensate into close contact, achieving equilibrium more quickly.
In a typical fractional distillation, a liquid mixture is heated in the distilling flask, and the resulting vapor rises up the fractionating column (see Image 1). The vapor condenses on glass spurs (known as trays or plates) inside the column, and returns to the distilling flask, refluxing the rising distillate vapor. The hottest tray is at the bottom of the column and the coolest tray is at the top. At steady-state conditions, the vapor and liquid on each tray reach a equilibrium. Only the most volatile of the vapors stays in gas form all the way to the top, where it may then proceed through a condenser, which cools the vapor until it condenses into a liquid distillate. The separation may be enhanced by the addition of more trays (to a practical limitation of heat, flow, etc.).
Image 1: Fractional distillation apparatus using a Liebig condenser
Fractionating columns help to separate the mixture by allowing the mixed vapors to cool, condense, and vaporize again in accordance with Raoult's law. With each condensation-vaporization cycle, the vapors are enriched in a certain component. A larger surface area allows more cycles, improving separation. This is the rationale for a Vigreux fractionating column or a packed fractionating column. Spinning band distillation achieves the same outcome by using a rotating band within the column to force the rising vapors and descending condensate into close contact, achieving equilibrium more quickly.
In a typical fractional distillation, a liquid mixture is heated in the distilling flask, and the resulting vapor rises up the fractionating column (see Image 1). The vapor condenses on glass spurs (known as trays or plates) inside the column, and returns to the distilling flask, refluxing the rising distillate vapor. The hottest tray is at the bottom of the column and the coolest tray is at the top. At steady-state conditions, the vapor and liquid on each tray reach a equilibrium. Only the most volatile of the vapors stays in gas form all the way to the top, where it may then proceed through a condenser, which cools the vapor until it condenses into a liquid distillate. The separation may be enhanced by the addition of more trays (to a practical limitation of heat, flow, etc.).
Friday, March 25, 2011
Tip #22 For Better Chemical Engineering: Six Sigma
Six Sigma is a business management strategy originally developed by Motorola, USA in 1986.[1][2] As of 2010[update], it is widely used in many sectors of industry, although its use is not without controversy.
Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes.[3] It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.) who are experts in these methods.[3] Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction or profit increase).[3]
The term Six Sigma originated from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes. The maturity of a manufacturing process can be described by a sigma rating indicating its yield, or the percentage of defect-free products it creates. A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million). Motorola set a goal of "six sigma" for all of its manufacturing operations, and this goal became a byword for the management and engineering practices used to achieve it.
Six Sigma seeks to improve the quality of process outputs by identifying and removing the causes of defects (errors) and minimizing variability in manufacturing and business processes.[3] It uses a set of quality management methods, including statistical methods, and creates a special infrastructure of people within the organization ("Black Belts", "Green Belts", etc.) who are experts in these methods.[3] Each Six Sigma project carried out within an organization follows a defined sequence of steps and has quantified financial targets (cost reduction or profit increase).[3]
The term Six Sigma originated from terminology associated with manufacturing, specifically terms associated with statistical modeling of manufacturing processes. The maturity of a manufacturing process can be described by a sigma rating indicating its yield, or the percentage of defect-free products it creates. A six sigma process is one in which 99.99966% of the products manufactured are statistically expected to be free of defects (3.4 defects per million). Motorola set a goal of "six sigma" for all of its manufacturing operations, and this goal became a byword for the management and engineering practices used to achieve it.
Friday, March 18, 2011
Tip #21 For Better Chemical Engineering: Intro to PFRs
In a PFR, one or more fluid reagents are pumped through a pipe or tube. The chemical reaction proceeds as the reagents travel through the PFR. In this type of reactor, the changing reaction rate creates a gradient with respect to distance traversed; at the inlet to the PFR the rate is very high, but as the concentrations of the reagents decrease and the concentration of the product(s) increases the reaction rate slows. Some important aspects of the PFR:
* All calculations performed with PFRs assume no upstream or downstream mixing, as implied by the term "plug flow".
* Reagents may be introduced into the PFR at locations in the reactor other than the inlet. In this way, a higher efficiency may be obtained, or the size and cost of the PFR may be reduced.
* A PFR typically has a higher efficiency than a CSTR of the same volume. That is, given the same space-time, a reaction will proceed to a higher percentage completion in a PFR than in a CSTR.
For most chemical reactions, it is impossible for the reaction to proceed to 100% completion. The rate of reaction decreases as the percent completion increases until the point where the system reaches dynamic equilibrium (no net reaction, or change in chemical species occurs). The equilibrium point for most systems is less than 100% complete. For this reason a separation process, such as distillation, often follows a chemical reactor in order to separate any remaining reagents or byproducts from the desired product. These reagents may sometimes be reused at the beginning of the process, such as in the Haber process.
Continuous oscillatory baffled reactor (COBR) is a tubular plug flow reactor. The mixing in COBR is achieved by the combination of fluid oscillation and orifice baffles, allowing plug flow to be achieved under laminar flow conditions with the net flow Reynolds number just about 100.
* All calculations performed with PFRs assume no upstream or downstream mixing, as implied by the term "plug flow".
* Reagents may be introduced into the PFR at locations in the reactor other than the inlet. In this way, a higher efficiency may be obtained, or the size and cost of the PFR may be reduced.
* A PFR typically has a higher efficiency than a CSTR of the same volume. That is, given the same space-time, a reaction will proceed to a higher percentage completion in a PFR than in a CSTR.
For most chemical reactions, it is impossible for the reaction to proceed to 100% completion. The rate of reaction decreases as the percent completion increases until the point where the system reaches dynamic equilibrium (no net reaction, or change in chemical species occurs). The equilibrium point for most systems is less than 100% complete. For this reason a separation process, such as distillation, often follows a chemical reactor in order to separate any remaining reagents or byproducts from the desired product. These reagents may sometimes be reused at the beginning of the process, such as in the Haber process.
Continuous oscillatory baffled reactor (COBR) is a tubular plug flow reactor. The mixing in COBR is achieved by the combination of fluid oscillation and orifice baffles, allowing plug flow to be achieved under laminar flow conditions with the net flow Reynolds number just about 100.
Thursday, March 17, 2011
Tip #20 For Better Chemical Engineering: Continuous Stirred-Tank Reactor
At steady-state, the flow rate in must equal the mass flow rate out, otherwise the tank will overflow or go empty (transient state). While the reactor is in a transient state the model equation must be derived from the differential mass and energy balances.In a CSTR, one or more fluid reagents are introduced into a tank reactor equipped with an impeller while the reactor effluent is removed. The impeller stirs the reagents to ensure proper mixing. Simply dividing the volume of the tank by the average volumetric flow ratethrough the tank gives the residence time, or the average amount of time a discrete quantity of reagent spends inside the tank. Usingchemical kinetics, the reaction's expected percent completion can be calculated. Some important aspects of the CSTR:
The reaction proceeds at the reaction rate associated with the final (output) concentration.
Often, it is economically beneficial to operate several CSTRs in series. This allows, for example, the first CSTR to operate at a higher reagent concentration and therefore a higher reaction rate. In these cases, the sizes of the reactors may be varied in order to minimize the total capital investment required to implement the process.
It can be seen that an infinite number of infinitely small CSTRs operating in series would be equivalent to a PFR.
The behavior of a CSTR is often approximated or modeled by that of a Continuous Ideally Stirred-Tank Reactor (CISTR). All calculations performed with CISTRs assume perfect mixing. If the residence time is 5-10 times the mixing time, this approximation is valid for engineering purposes. The CISTR model is often used to simplify engineering calculations and can be used to describe research reactors. In practice it can only be approached, in particular in industrial size reactors.
The reaction proceeds at the reaction rate associated with the final (output) concentration.
Often, it is economically beneficial to operate several CSTRs in series. This allows, for example, the first CSTR to operate at a higher reagent concentration and therefore a higher reaction rate. In these cases, the sizes of the reactors may be varied in order to minimize the total capital investment required to implement the process.
It can be seen that an infinite number of infinitely small CSTRs operating in series would be equivalent to a PFR.
The behavior of a CSTR is often approximated or modeled by that of a Continuous Ideally Stirred-Tank Reactor (CISTR). All calculations performed with CISTRs assume perfect mixing. If the residence time is 5-10 times the mixing time, this approximation is valid for engineering purposes. The CISTR model is often used to simplify engineering calculations and can be used to describe research reactors. In practice it can only be approached, in particular in industrial size reactors.
Wednesday, March 16, 2011
Tip #19 For Better Chemical Engineering: Chemical Reactors
In chemical engineering, chemical reactors are vessels designed to contain chemical reactions. The design of a chemical reactor deals with multiple aspects of chemical engineering. Chemical engineers design reactors to maximize net present value for the given reaction. Designers ensure that the reaction proceeds with the highest efficiency towards the desired output product, producing the highest yield of product while requiring the least amount of money to purchase and operate. Normal operating expenses include energy input, energy removal, raw material costs, labor, etc. Energy changes can come in the form of heating or cooling, pumping to increase pressure, frictional pressure loss (such as pressure drop across a 90o elbow or an orifice plate), agitation, etc.
Chemical reaction engineering is the branch of chemical engineering which deals with chemical reactors and their design, especially by application of chemical kinetics.
There are a couple main basic vessel types:
- A tank
- A pipe or tubular reactor
Both types can be used as continuous reactors or batch reactors. Most commonly, reactors are run at steady-state, but can also be operated in a transient state. When a reactor is first brought back into operation (after maintenance or inoperation) it would be considered to be in a transient state, where key process variables change with time. Both types of reactors may also accommodate one or more solids (reagents, catalyst, or inert materials), but the reagents and products are typically liquids and gases.
There are three main basic models used to estimate the most important process variables of different chemical reactors:
- batch reactor model (batch),
- continuous stirred-tank reactor model (CSTR), and
- plug flow reactor model (PFR).
Furthermore, catalytic reactors require separate treatment, whether they are batch, CST, or PF reactors, as the many assumptions of the simpler models are not valid.
Key process variables include
- Residence time (τ, lower case Greek tau)
- Volume (V)
- Temperature (T)
- Pressure (P)
- Concentrations of chemical species (C1, C2, C3, ... Cn)
- Heat transfer coefficients (h, U)
A chemical reactor, typically tubular reactor, could be a packed bed. The packing inside the bed may have catalyst to catalyze the chemical reaction. A chemical reactor may also be a fluidized bed; see Fluidized bed reactor.
Chemical reactions occurring in a reactor may be exothermic, meaning giving off heat, or endothermic, meaning absorbing heat. A chemical reactor vessel may have a cooling or heating jacket or cooling or heating coils (tubes) wrapped around the outside of its vessel wall to cool down or heat up the contents.
Via {link}
Friday, February 25, 2011
Tip #19 For Better Chemical Engineering: Overview
It would take too long to list all the products that are impacted by chemical engineers, but knowing what industries employ them may help you comprehend the scope of their work. Chemical engineers work in manufacturing, pharmaceuticals, healthcare, design and construction, pulp and paper, petrochemicals, food processing, specialty chemicals, polymers, biotechnology, and environmental health and safety industries, among others. Within these industries, chemical engineers rely on their knowledge of mathematics and science, particularly chemistry, to overcome technical problems safely and economically. And, of course, they draw upon and apply their engineering knowledge to solve any technical challenges they encounter.
Don't make the mistake of thinking that chemical engineers only make things, though. Their expertise is also applied in the area of law, education, publishing, finance, and medicine, as well as many other fields that require technical training.
Specifically, chemical engineers apply the principles of chemistry to solve problems involving the production or use of chemicals and other products. They design equipment and processes for large-scale chemical manufacturing, plan and test methods of manufacturing products and treating byproducts, and supervise production.
Chemical engineers also work in a variety of manufacturing industries other than chemical manufacturing, such as those producing energy, electronics, food, clothing, and paper. In addition, they work in healthcare, biotechnology, and business services. Chemical engineers apply principles of physics, mathematics, and mechanical and electrical engineering, as well as chemistry. Some may specialize in a particular chemical process, such as oxidation or polymerization. Others specialize in a particular field, such as nanomaterials, or in the development of specific products. They must be aware of all aspects of chemical manufacturing and how the manufacturing process affects the environment and the safety of workers and consumers.
Chemical engineers face many of the same challenges that other professionals face, and they meet these challenges by applying their technical knowledge, communication and teamwork skills, the most up-to-date practices available, and hard work. Benefits include financial reward, recognition within industry and society, and the gratification that comes from working with the processes of nature to meet the needs of society.
Source: http://www.careercornerstone.org/chemeng/chemeng.htm
Don't make the mistake of thinking that chemical engineers only make things, though. Their expertise is also applied in the area of law, education, publishing, finance, and medicine, as well as many other fields that require technical training.
Specifically, chemical engineers apply the principles of chemistry to solve problems involving the production or use of chemicals and other products. They design equipment and processes for large-scale chemical manufacturing, plan and test methods of manufacturing products and treating byproducts, and supervise production.
Chemical engineers also work in a variety of manufacturing industries other than chemical manufacturing, such as those producing energy, electronics, food, clothing, and paper. In addition, they work in healthcare, biotechnology, and business services. Chemical engineers apply principles of physics, mathematics, and mechanical and electrical engineering, as well as chemistry. Some may specialize in a particular chemical process, such as oxidation or polymerization. Others specialize in a particular field, such as nanomaterials, or in the development of specific products. They must be aware of all aspects of chemical manufacturing and how the manufacturing process affects the environment and the safety of workers and consumers.
Chemical engineers face many of the same challenges that other professionals face, and they meet these challenges by applying their technical knowledge, communication and teamwork skills, the most up-to-date practices available, and hard work. Benefits include financial reward, recognition within industry and society, and the gratification that comes from working with the processes of nature to meet the needs of society.
Source: http://www.careercornerstone.org/chemeng/chemeng.htm
Thursday, February 24, 2011
Tip #18 For Better Chemical Engineering: Career Guidance
Pre-University students should take as many math and science courses as possible, both during school and as part of after-school programs. Students aged 5-9 should do additional math, puzzles, and building or design projects. Students aged 9-12 should take extra math, and if inspired, explore pre-algebra and geometry. Students aged 12-18 might consider taking advanced algebra, chemistry, calculus, geometry, trigonometry, physics, building, design, and engineering concept courses.
There are also several lessons and activities, and projects and competitions that can help provide students with an interest in engineering first hand exposure to electrical engineering principals. Students who implement these activities and participate in projects or competitions have a better understanding of engineering and its impact on society. They'll be better able to determine if engineering is the career path for them by sharing their interest with other students, and experiencing hands-on applications of engineering. Summer programs and internships are another great way for students at the pre-university level to explore engineering.
There are also several lessons and activities, and projects and competitions that can help provide students with an interest in engineering first hand exposure to electrical engineering principals. Students who implement these activities and participate in projects or competitions have a better understanding of engineering and its impact on society. They'll be better able to determine if engineering is the career path for them by sharing their interest with other students, and experiencing hands-on applications of engineering. Summer programs and internships are another great way for students at the pre-university level to explore engineering.
Tip #17 For Better Chemical Engineering: Be Curious
Lastly I am going to say be curious. Be curious about problems, be curious about solutions, and be curious about all those tools (equations, connectors, and machine tools) that will help you find solutions to problems. If you let your mind just sit waiting for a solution to easily manifest itself, it won’t. You have to be curious and be active about wanting to become a better engineer.
I plan on posting a lot of the things I have learned during my first few years as an engineer within this blog category. I am trying to remain open to new solutions everyday and not believe that what I learned in college will get me through tomorrow. I hope to learn ten times the amount about processes that are out there within the next year and another 10 times that the next. Only then will I begin to easily see creative solutions to some of those most difficult problems.
Other Interesting Articles and Categories:
Become Good at Everything - A How-to
Starting a Business
Setting Intermediate Goals
Source: http://www.erikvossman.com/
Wednesday, February 23, 2011
Tip #16 For Better Chemical Engineering: Know your tools
If you want to sit around and do equations all day then go to a big name school that’s completely hands-off. If you want to learn how to engineer things and design great things then don’t say no when someone says you want to get some Machine Shop time. Those really greasy rough looking guys/gals that spend all day turning cranks and programming CNC machines (CNC stands for computer numerically controlled) could probably design circles around some of the A+ engineers that have come out of top schools like Michigan. If you know a person who works as a machinist, pick his or her brain and try to get them to show you around a mill or a lathe for a bit. It will be the most informative Saturday afternoon you could have.
Don’t be afraid of the tools that are out there. Even if you don’t pick on up know what they are, how they work, and how best to design for them. When I first arrived at Tissue Genesis, Inc I was told to redesign a plastic molded piece that used a heat staker and a sonic welder. I had no idea what these machines were let alone how to design for them. Then I began calling companies, asking for design tips, sheets that showed design tips, googling everything I could, and basically asking as many questions as possible. In the end I was able to redesign the piece (actually 10 down to 7 main pieces) sonic weld 2 pieces onto a larger one and save $15 a disposable in the heat staking procedure. That was all from just asking a lot of questions and learning about all the tools that are out there.
Some great catalogs to get you started are:
McMaster Carr
MSC Industrial Tools
Tip #15 For Better Chemical Engineering: Taking things apart
A big thing I learned in my last year of undergrad and I continue to notice on the job is that people who take things apart are able to find more solutions. This stems from knowing what’s out there. If you take say a typical desktop computer apart you know that there are a lot of circuit boards, come wiring harnesses, and a fan. That would be one way to look at it. But if you begin to look at each board you see what type of surface mount resistors were used, what processor was used, are there gold leads? Then you look at the wiring harness; what type of connectors were used and why do you think they were used, is the wire stranded or single, can the connectors withstand humidity? Then you look at the fan; where is it placed, why is it in that location, how much power does it consume? Then you begin to look at the whole computer tower and how the parts fit together; why is a board where it is, what about the wiring routes, what looks like it needs the fan the most, will the computer stop running if you place the fan in a different location?
Once you begin to look at the interconnections of each of the pieces you begin to realize why the engineers responsible for it used it. Then, and this can make you some money, you may see a solution to a problem that the current design causes. If you take enough things apart or read enough about how things are made you will have more solutions to the problems you face as an engineer. Good things to take apart are, radios, printers, clocks, TVs, engines, phones, keyboards, computers, speakers, toasters, phones, drills, air tools, and anything else that interests you.
WARNING: Some of the above mentioned items can shock the crap out of you and cause some wicked damage, please be careful and don’t take it apart without consulting someone who knows about it or a super online resource.
Super Online Resources:
HowStuffWorks.com
About.com
Bill Nye the Science Guy
Wikipedia.org
Source: http://www.erikvossman.com/
Tuesday, February 22, 2011
Tip #14 For Better Chemical Engineering: Online Resources
A few of the online resources that are key for any Chemical Engineer:
www.lib.berkeley.edu/CHEM/
http://www.mcmaster.com/
Keep these around at all times and use them as much as possible to solve any problem!
Tip #13 For Better Chemical Engineering: Problem Solving
First off you should want to solve problems. If you don’t like to solve problems you are going to most likely be miserable as an engineer. If you are in classes right now you are probably wondering, as I did, why the heck your professors are making you do problem sets that take 10-15 hours to complete, and make you search several sources (textbooks, computer programs, online resources, even scientific papers) to complete one single problem. Well the answer to this is one they never told me during my years at Michigan, or at least not loud enough it would wake me up.
You do all that problem solving and looking up to train your mind to look at problems from all angles. Of course you’re never going to be asked to solve a mass transfer problem without referencing a formula, but if you know that the formula is there, you can begin to see the problem from that angle before you even know the answer. Think of all those problems you are doing as a way to increase your mental toolbox. Every ME problem you do, or CHE problem allows you another look at a very similar problem. You’ve also more than likely said, “All these problems are the same” in some sort of frustration. When you’re on the job you may only have access to 50% of the tools needed. If you didn’t do problems to prepare yourself you wouldn’t be able to tell your boss, he who signs you paychecks and OKs bonuses, “here’s the answer, if we just go at it from this obscure angle it’s simple.”
Monday, February 21, 2011
Tip #12 For Better Chemical Engineering: Early Start
Becoming a good chemical engineer isn’t something that will happen straight out of college (takes a lot of bumps to make it work!), some may say you are born with the skills; that may be partly true, but I believe you need to acquire the thought process that engineers have through years of experience. You can speed up the process if you know what to look for and how to handle problem situations.
I have always liked math growing up and once I got to college figured I should go into some sciences. Plus reading wasn’t a big priority for me yet. Engineering seemed like a good fit because it seemed like the most rewarding. Becoming an engineer offers you the opportunity to learn the skills needed to be the designer of things, get patents, get your name written into history books, literally. There are many disciplines to choose from such as mechanical, chemical, electrical, civil, etc. I chose Chemical Engineering because of its being the oldest and most demanded general engineering.
That’s neither here nor there though. You came here most likely to learn HOW TO BECOME A GOOD ENGINEER, MAYBE EVEN GREAT. Well, I won’t give you any sure fire way but I will give it all away!
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