Applied first principle approach to problem solving for Chemical/Process Engineers

1. Chemical Engineering
Hat & Mind
Engr. Akachidike Kanu
Webinar Lecture presented to:
Nigerian Society of Chemical Engineers – Rivers-Bayelsa Chapter
29th June 2021

2. core
Cap fit
Mind
shift

3. Premise
• Nominal (worker)
• Responsibility
• Fort
• Profile /Status
• “Best Practice”
• Fundamental (problem
solver)
• Requirement
• Turf
• Process/”Dynamus”
• “First Principles”
Motivation
Technical Skills
Problem Solving & Critical Thinking
Industry Knowledge
Communication Skills
Keys to
employability
and success
Hat
Mind
First Principles
Application Skill
Technical Skills
Problem Solving
and Critical
Thinking
Outline: Job description | Pro profile |Application cases | Industry outlook

4. JDs – Roles Responsibilities
• Apply chemical engineering principles, computational modeling tools, and
experimental skills using data-rich lab instrumentation to develop robust unit
operations and improve process understanding.
• Apply an understanding of large-scale manufacturing equipment capabilities and
operations to assess scalability and robustness for API processes.
• Support technology transfer of processes to internal Pfizer Global Supply (PGS)
API manufacturing facilities and external suppliers. May spend time at the PGS
launch site supporting process validation and Pre-Approval Inspection (PAI)
activities.
• development of novel laboratory instrumentation and computational modeling
tools to improve process understanding. Support the development and
implementation of new and existing workflows and methodologies.
• Working with team members with expertise in process modelling and in statistics,
design and execute Design of Experiments (DoE) methodology using automated
lab reactor systems. Use data from these experiments to understand reaction
mechanisms, to build reaction kinetic models, and to understand the kinetic and
thermodynamic factors impacting various separation unit operations such as
extraction, distillation, crystallization, and drying.
• Biotech & pharma
• Energy & Utilities
• Semiconductors
and electronics
• Petrochem &
refining
• EPCI / consultancy
• Environment
• Chemicals
• FMCG, food, agro
processing
• Mining
• Management
Consulting
• R&D
• Government
• Etc

5. JDs – Requirements
Basic Qualifications
• MS in Chemical Engineering or BS in Chemical Engineering with 2-4 years of
experience.
• Strong knowledge of chemical engineering principles including reaction kinetics,
reactor design, chemical thermodynamics, heat and mass transport, engineering
statistics, process modeling and simulation.
• Excellent interpersonal, teamwork, and communication skills
Preferred Qualifications
• Working knowledge of reaction modeling, property prediction, and simulation
computational tools including: DynoChem, VisiMix, Aspen, M-Star, and
COSMOtherm
• Working knowledge of analytical techniques such as HPLC/UPLC, MS, PXRD, DSC,
TGA, and NMR
• Experience in automating lab equipment and processes including use of LabView
• Experience using automated lab reactor systems
• Working knowledge of application of in-situ analysis tools to process
understanding including: FTIR, FBRM, UV/Vis
• A good foundational understanding of organic chemistry
• Biotech & pharma
• Energy & Utilities
• Semiconductors
and electronics
• Petrochem &
refining
• EPCI / consultancy
• Environment
• Chemicals
• FMCG, food, agro
processing
• Mining
• Management
Consulting
• R&D
• Government
• Etc

6. An epiphany of the ChE’s most
valuable resource
Fluid mechanics and pipe flow
Process safety & loss
prevention
Separation processes & equip.
Instrumentation and control
Plant design documents, etc
• Process and equipment description
• Operations manuals
• P&IDs, data sheets,
• Control philosophy
• Data sheets
Images for illustration only

7. Applied “First Principles Thinking”
“Poundo”, lube-disinfectant, cosmetics – drying, bleaching and solvency,
detergency
• Product development engineering (entrepreneur)
Herbicides, deordorizer, EPC - Stoic, H&M, flowsheets, VT
• Resource Person – process design – NARICT
• Process Engineer – O&G engineering consultancy
Project, construction, drilling, reservoir, ventures – Process, design, thermo, cost,
stat, economics, execution
• Facilities/Project Manager/Engineer/Coordinator
• Concept, Opportunities & Development engineer
• “Integrator”
Decision support, portfolio, ventures, base business and asset
• FE Engineer/Manager,
• Projects Leader, Technical Advisor
Integrated technical + business leadership

8. Credit: Kanu et al IPTC-17492-MS, 2014
A-1
A-2
Mitigation of Gas Hydrate

9. Credit: Kanu et al IPTC-17492-MS, 2014
Traditional inhibitor
systems & challenges
• THI, LDHI, KHI, AA
• Cost, volume, safety
• Wct restrictions,
model predictability
• Toxicity,
biodegradability,
reservoir fouling, etc
A Zero-Cost
Solution
(Value not volume)

10. Credit: Kanu et al ASME OMAE 2018
Courtesy IHS Questor 2017 Q3
ASME/ANS B31.8
ASME 16.5
API 5L
Deepwater
Gas
Pipeline

11. Credit: Kanu et al ASME OMAE 2018
0
10
20
30
40
50
0 4 8 12 16 20 24 28 32 36
WT
(mm)
NPS (Inches)
0
100
200
300
400
500
600
700
800
900
0 10 20 30 40
Pressure
Drop
(bara)
NPS (inch)
Op. Line!
Sys. Curve!
“Theoretical” Pipe Size

12. It Works!
Warren L. McCabe and Ernest Thiele (1925)
Credit: Baba et al, King Saud Univ

13. Credit: Kanu et al ASME OMAE 2018
“Theoretical” Optimum Pipe Size
0
10
20
30
40
50
0 4 8 12 16 20 24 28 32 36
WT
(mm)
NPS (Inches)
0
100
200
300
400
500
600
700
800
900
0 10 20 30 40
Pressure
Drop
(bara)
NPS (inch)
Op. Line!
Sys. Curve!

14. MB
Shuttle
Tankers
Storage
Tank
-45,000
-40,000
-35,000
-30,000
-25,000
-20,000
-15,000
-10,000
-5,000
0
5,000
1 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 0
Thousand
barrels
of
oil
Shuttle ships per year
Shutlle Tanker Fleet Optimisation
Cumm system holdup (kbbl) Tank holdup (kbbl) Storage Tank Cap (kbbl)
year1 year2 year3 year4 year5 year6 year7 year8 year9 year10 year11 year12 year13 year14 year15 year16 year17 year18 year19 year20 year21
26 39 52 57 56 40 27 20 16 13 12 11 10 9 9 8 8 7 7 6 1
408 408 408 408 408 408 408 408 408 408 408 408 408 408 408 408 408 408 408 408 408
16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16
2 3 5 6 6 5 4 3 2 2 2 2 2 2 2 2 2 2 2 2 2
Accum = In – Out + Gen
$10,000 MM
A Transport Phenomena

15. Proc.
D&A
PM
Methodology
PM
Process
$XX,XXX MM
Credit: Chevron . Source: Financial Chronicles - Weebly
Waterfall
Lean Agile
Scrum
Scrumban
Extreme Programming
(XP)
Crystal
Method
Structured
Agile Dynamic Systems Development
Method (DSDM)
Critical Path Method
(CPM)
Rapid Action
Development
Integrated Project
Management

16. Summary Project Status: Forecast v. Actual to Date
Scope Jul -21 For the Year 2021 Total Project
Forecast Actual Forecast Actual Forecast Actual
Hat & Mind $300,000 $1,465,355 $5,273,886 $4,623,887 $14,711,512 $11,382,720
ABC $10,000 $14,969 $157,924 $137,924 $1,009,047 $3,252,841
ChE $10,000 $0 $768,125 683,125 $8,283,752 $8,178,752
Total $1,848,289 2,469,236 $22,064,262 $18,079,261 $59,790,579 $52,140,579
Project
M&C

17. Two things
defining the future of
industry

18. “Climate Age”
(A green revolution)

19. Digitalization – “Industry 4.0”

20. Thank You
With all my Hat!

21. Q & A