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WHAT IS CHEMICAL ENGINEERING

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• ChEg. is a multidisciplinary subject aimed towards design of industrial processes and systems that change raw materials/inputs into more useful and marketable products/services economically, safely and in an environmentally acceptable way.

• . ChEg involves developing and designing processes, specifying equipment, operating conditions,instrumentation, process control and evaluating the economics of an industrial plant

• This broad definition of ChEg will help to include soap, detergent, silicate, Sugar, paper, petroleum ,plastics, synthetic fibers, fertilizers, pesticide, paint,cement, glass, ceramics and other allied process industries in addition to chemicals

CHEE 2404:Industrial Chemistry 10

Engineering +Economics

ChEg Combines the principles of mathematics, physics, chemistry and biology with engineering practices and economics in order to improve the human environment.

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Che ·ca E g·nee g:

Como· es the pr·nciples of ma hema ·'cs,p ys·cs , chemis ry and b io ogy w"thengineer "ng p c ices ·n order

e uman env •ronmeno ·mprove

Biology

12

Application of basic natural and social sciences (math, chemistry,

physics , biology & Economics ) and engineering principles to the

development, design, operation & maintenance of processes to

convert raw materials to useful products and improve the human

develo•pm. ent and environment.

Physics

Economics

Agriculture

Water

Air

Natural Gas

Petroleum

Coal

Minerals

MathematicsChemistry

Energy

Chemical Engineering

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13

Curriculum• Basic Sciences

– Mathematics, Physics, Chemistry,Biology

• Engineering Sciences and Designs

– Thermodynamics (Heat, work, phase equilibrium, chemical equilibrium)

– Transport Phenomena (heat transfer, fluid mechanics, mass transfer)

– Numerical Analysis

– Computer-Aided Design

– Chemical Reaction Engineering

– Process Industries

– Process Control and Automation

– Process &p lant Design

Engineering Economics & managment

14Unit 2: An Overview of Process Technology

peeeeeeolyurethane

The Chemical Engineering products tree

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Significant Achievements of Chemical Engineering1.Feedig the world-------fertilizers, biotechnology,processing2. Clothing the world---- Sythetic fibers, shoes

food

3.Housing the world ----- Cement,glass,paints,plastics

3. Keeping the health of the world-----Low price, high volumeChemical drugs /97%/

5. Transporting the world----- gasoline, diesel,Tyre

6.The plastic age------------ (bakalite, polyethylene,polystyrene/communication/computer...)

7. Synthetic rubber (gaskets, hoses, conveyor belts,)

8.Protecting mother earth-----(catalytic converters, wastetreatment)9. Production of IT products (storage devices, microelectronics, 10.Artificial organs and biomedical devices

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CHEE 2404:Industrial Chemistry 17

FILLERSPlastics

Rubber

Fiber

Paints4

1 Monomer & Co-monomerProduction

Solvent CatalystMONOMERS

COMONONERS

2

3 Compounding

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CHEE 2404:Industrial Chemistry 19

What is a Chemical Engineer?

A Chemical Engineer ---*who creates & manufactures

chemicals and allied products

*who creates and manages chemicals

and allied industries

With out leading role of chemical Engineers.No Adequate food (7.0 b mouths) ----FetlizersNo Adequate clothes ----syn. fiber ,leather

No decent housing--Cement,glass,paints

No Adequate health---Pharm.chemicalsNo potable water– lime,ChlorineNo Adequate energy-Pertoleum/Biofuel

No modern world with out chemical (Petroleum,Tyres,plastics,soap/Detergent Compueter,…

It is a Chemical Engineering World!

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Life = Food = Fertlizers ( N2,P2O5 &K2O)

22

Urea

fertilizer

plant

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23Potash

Urea

24Urea2NH3 + CO2––––––––––– CO (NH2)2 + H2O

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CHEE 2404:Industrial Chemistry 25

Sugar industris

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There are

>600 additives

No decent housing- -Cement ,glass

c e m e n tp r oc ess -t e ch n o Io g y

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No modern world t h out chemical Ind.

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P a i n t s R u b b e r F a b r i c s P l a s t i c s

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Petoleum and Petrochemical Industries

Products Made from a Barrel ofCrude Oil (Gal lons)(2009)

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The global vision of the bio-economy foresees an annual revenue growth for biofuels of 15%, biochemicals 12%and biomaterials 14% for the year 2010,and by 2030 biomaterials projected growth was 25%.

Mercedes-Benz automobiles have more than 30 parts made of natural fibres

Modern life/Transport= Petroleum Products

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Chemical Engineering Education

EconomicsHumanities

Engineering/Science Core

Sugar Technology

Cement Technology

LeatherTechnology

Petroleum Eng

Polymer S&T

The chemical engineering education needs to respond to the industrial realities of the profession.

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The strong scientific, mathematical, and technicalbackground found in chemical engineering education is allowing the profession to enter new fields Such as Biotechnology, electronics, material Eng.

The largest growth in employment is occurring in up-and-coming fields which show tremendous potential in

All offer possibilities for chemical engineers.

Current Trends and direction:

Process Eng. Petoleum Eng,Environmental Eng. polymer S& TFood Eng., Biotechnology, Fertlizer Tech.electronics, catalyst Dev.Reactor design, pharmaceuticals,Leather technology Sugar Technology CementTech.Matreial Eng nano technologies.

What are the fields of Ch Eg?

The traditional fields of ChEg are:

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• Chemicals and allied products

• petrochemicals, petroleum and natural

gas processing

• plastics and polymers

• pulp and paper

• instrumentation and process control

• energy conversion and utilisation

• environmental control

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What are the fields of Ch Eg? Cont’d

39

• Biotechnology

• Biomedical and Biochemical

• food processing

• Sugar technology

• composite materials, corrosion and protective

coatings

• manufacture of microelectronic components

• Pharmaceuticals

What do Chemical Engineers do?

Thus, they are involved in a wide range of

activities such as:

• design, development and operation of

process plants

• research and development of novel

products and processes

• management of technical operations and

sales40

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World chemicals production, 2004

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• Chemical engineer is either currently, or

has previously, occupied the CEO

position for: BASF

Dow Chemical

Du Pont

ExxonMobile

Shell,Total

Texaco

Gulf Oil

Union Carbide

Bayer

B.F. Goodrich

Bridge Stone

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Where do Chemical Engineers work?The majority of Chemical Engineers work in

businesses known collectively as the Chemical Process

Industries (CPI)– Chemicals,– Oil and Gas (upstream and downstream)– Pulp and Paper,– Rubber and Plastics,– Food and Beverage,– Textile,– Electronics/IT– Metals, mineral processing– Electronics and microelectronics– Agricultural Chemicals Industries– Cosmetics/ Pharmaceutical– Biotechnology/Biomedical

– Environmental, technical, and business consulting

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• Production and utilization of energy• Advanced materials (catalysts, alloys,

enzymes, nanomaterials...)• Manufacture of chemicals (dyes, paints,

fertilizers, acids....)• Consulting• Metallurgy• perfumes and flavors• Instrumentation Development and

Marketing• Government• Patent Law

46

Where do Chemical Engineers work?

• Many Chemical Engineers also work in supplier,

consulting and governmental agencies related to the CPI

by engaging in equipment manufacture, plant design,

consulting, analytical services and standards

development.

• Chemical Engineers hold lead positions in industrial

firms and governmental agencies concerned with

environmental protection since environmental problems

are usually complex and require a thorough knowledge

of the Social Sciences, Physics, Biology, Mathematics

and Chemistry for their resolution.

• Chemical engineers have been referred to as “universal

engineers.”

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Pulp

)

Where do the chemical engineers work?

45% do ``traditional'' ChE: chemical,petroleum, plastic, paper, consumer goods

35% do ``new'' ChE: environment,consulting, microelectronics,biotechnology, materials

10% go to ChE graduate school

10% go to other graduate school(business)

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49

How much money do Chemical

Engineers make? Starting salaries (USA)

The National Association of Colleges and Employers (NACE) reported that, between Sept 1999 - Jan 2000, the average starting salary offer made to graduating chemical engineering students in the USA was:

• $49,418 with a Bachelor's degree

• $56,100 with a Master's degree

• $68,491 with a Ph.D.

Engineering ProfessionBachelor's

DegreeMaster's Degree Ph.D.

Wages comparison 2006 figures/USA

Aerospace $50,993 $62,930 $72529

Agricultural $46,172 $53,022

Biomedical $48,503 $59,667

Chemical $53,813 $57,260 $79,591Civil $43,679 $48,050 $59,625

Computer $52,464 $60,354 $69,625

Electrical $51,888 $64,616 $80,206

Environmental $47,384

Materials $50,982

Mechanical $50,236 $59,880 $68,229

Mining $48,643

Nuclear $51,182 $58,814

Petroleum $61,156 $58,000

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• The "unit operations" concept had been latent in the chemicalengineering profession ever since George Davis had organizedhis original 12 lectures around the topic.

• But, it was Arthur Little who first recognized the potential ofusing “Unit Operations" to separate chemical engineering fromother professions

• While mechanical engineers focused on machinery, andchemists concerned themselves with laboratory works andindividual reactions, no one, before chemical engineers,had concentrated upon the underlying processes commonto all industrial products, reactions, and machinery.

• The chemical engineer, utilizing the conceptual tool of unitoperations, could now make claim to industrial territory byshowing his or her uniqueness and worth to themanufacturer. 51

Unit operations

52

Unit operations• In transforming matter from inexpensive raw

materials to highly desired products, chemical engineers became very familiar with the physical and chemical operations necessary in this metamorphosis.

• Examples of this include:

– Distillation

– Crystallization

– Grinding

– Sedimentation

– Combustion

– Catalysis

– .

Evaporation

heat exchanger

Chlorination

Sulphonation

Saponification

Polymerization

Physical &

Chemical

operations

– filtration Adorption

– drying Absorption

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OVER VIEWS OF

•CHEMICAL & ALLIED

•INDUSTIES OF

ETHIOPIA

*Opportunities+ Challenges

OVER VIEWS OF CHEMICAL & ALLIED INDUSTIES OF ETHIOPIA

There are about 200 chemical and allied industries in Ethiopia,

most of them small private chemical related process industries.

Basic chemical industries such as Aluminum Sulphate & Sulphuric

acid, Caustic Soda and Soda ash, plastics, plastics, rubber, soap

and detergents, as well as those or Silicate industries such as

cement, glass and ceramics form the greater share of the

production value of the chemical sector of Ethiopia.

The most important chemical and allied products

manufactured by the chemical sector of Ethiopia are

presented below in accordance of their origin of

raw material.

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.1. LOCAL RAW NATERIAL BASE CHEMICAL

INDUSTRIES of EthiopiaAbijata Soda Ash Enterprise

Ethiopian Spice Extraction

Fincha and Metehara EthanolSugar

plantsTabor Ceramic Industries

Glass Industries

Zeway Caustic SodaCement Industries

FOREIGN AND LOCAL RAW MATERIAL BASE ChemicalINDUSTRIES of ETHIOPIA

Alkyd resin Factory /Linseed oil

Reppi and other Detergent plant /Caustic

sda

Awash MelkassaAluminium Sulphate and

Sulphuric acid Factory / Water & AirIndustrial gases (Carbon dioxide)

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FOREIGN BASE RAW MATERIAL CHEMICAL

INDUSTRIES OF ETHIOPIA

Horizon Addis Tyre and other Rubber

Processing IndustriesPlastic and Foam Processing Industries

Ethiopian pulp & Paper Industry

Adami Tulu Pesticides Formulation PlantPharmaceutical Industries

Paints IndustriesSoap and Detergent Industries

Summary of major Indicators of Chemical Industries in EthiopiaParameters A. Total B. Chemical an d allied industries

Chemical Rubber

and

Plastics

Paper

products

Total

Chemical

and

allied

B/A%

No. of

Establishment

1930 80 82 20 182 9.43

Fixed Assets

( No. 1756)

Billion Birr

8.26 0.46 0.69 0.09 1.14 13.8

Gross Value of

Production Billion

Birr

22.49 1.73 1.45 0.44 2.63 11.7

Production cost,

Billion Birr

13.82 1.20 1.04 0.30 2.54 18.4

Value added

cost,Billion Birr

9.17 0.53 0.41 0.14 1.09 11.9

No. of Employees 131,803 7 762 1960 8 727 18449 14.0

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Gross Value of Industrial Production of Ethiopia

(2007) = 22.5 Billion Birr (2 billion USD )

Gross Value of Chemicl Production of Ethiopia

(2007) = 2.6 Billion Birr/0.23 billion USD or $230millonComparison

Annual sales of Toyota ( 2007) =180 billion USDAnnual sales of Total ( 2007)Annual sales of Nokia ( 2007)

= 175 billion USD= 75 billion USD

The Challenge Of ChemicalEngineering in Ethiopia

3. RESOURCE BASE FOR THE

DEVELOPMENT OF CHEMICAL

INDUSTRIES IN ETHIOPIA

• *Opportunities+ Challenges

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1. RAW MATERIAL RESOURCES

Raw materials employed in the production of chemical and allied

products are among the most important inputs to chemical and

allied industries.

The basic raw materials for chemical and allied products are

classified into two groups

Agricultural raw materials: plant and

animal organs

Mineral raw materials: Oil, Natural

gas,Coal, Metals and Non-metal

Atmospheric Raw materials: N2, O2

1.Agricultural Raw MaterialsThe variation in climate condition ranging from tropical

low lands to highlands makes Ethiopia potential country

to grow almost any type of vegetation and to raise

different animal species

Hence the agricultural resources of Ethiopia can serve

as potential basis for the supply of raw materials to

develop and establish chemical and allied industries in

the country.

Ethiopia’s Agricultural undeveloped, unscientific and

uncommercialized in large scale for industrial production

and business modalities.

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Potential agricultural raw material for establishing chemical and

Corn: Staraclhli,egdluincdousset,rdieesxtinroEsteh,iToepxiati.le Chemicals

Tanning bearing plants: Tanning Chemicals

Essential bearing plants: Essential oils cosmetics

Sugar: Sucro Chemicals

Molasses: Ethanol and ethanol base chemicals,

Ethanol: various chemicals including plastics

Resin bearing plants / acacia: water based adhesives

Castor & other vegetable oils : Biodiesels, leather

ChemicalsAnimal Fats & oils: fatty acids, glycerin

Animal by-products: Glue, phosphoric acid

Waxes: Polishes

Civets: Fixative agents

2. Mineral raw materials

In the context of mineral resources, Ethiopia is unexplored and

unexploited country.

The only exception is that of the non metallic minerals

Calcium Carbonate, Silica, Feldspar, Kaolin and Soda ash

which are currently used in the production of Aluminum Sulphate

Casutic Soda, Cement, glass, ceramics and lime.

Coal and Natural gas are at sights far from the current usage

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A number of Ethiopian minerals which at first glance, could serve as

raw materials for future chemical industries in Ethiopia are

presented below

Potash: Fertlizers- Loquid Soap

Phosphate------- Fertlizers, rgano Phospate Pesticides

Coal/lignite------ Fertlizers , Hydrocarbon Chemicals

Natural gas------ Fertlizers , Hydrocarbon Chemicals

Sodium Chloride------NaOH,Cl2, HCl,Plastics, Berekina

Lime stone------- Cement

Soda ash---------- Glass,

Fieldspar/Kaolin ---------- Ceramiic

Sulphur------------Sulphuric acid

Gypsum-------------Chalk

Datomite ---------------Absorbent &Filter aid Chemicals

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Trends of chemical and allied process industries inEthiopiaChemical and allied industries planned in the (TP of 2010-2015.

•Fertilizer Complex Plant------Capacity 300,000 ton urea/year

•Caustic soda Plant:------------ Capacity 50,000 ton/year

•Soda Ash Plant--------------------Capacity 35,000 ton ton/year

•Soap and Detergent Plant:-----Capacity 166000 ton ton/year

•Paper Pulp Plant:------------------Capacity 31 500 ton ton/year

•Paper plant--------------------------Capacity 41 000 ton ton/year

•Poly ethylene plant-------------- Capacity35 000 ton ton/year

•Natural Rubber Latex Plant-----Capacity 6700 ton ton/year

•Sugar Processing Industries------------------- 12 plantsNational capacity will reach 2.25 million tons in2015

Current national capacity about 0.315 million tons (2010)

Production will increase by 1.935 million tons

• Ethanol PlantNational capacity will reach 304 000 m3 in 2015

Current National Production capacity 30 124 m3 (2010)

•Cement Processing Industries

•National capacity will reach 27 million tons in 2015

•Current national capacity about 3 million tons (2010)

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Major goals of Chemical and Allied Process Industries

development in the Growth and Tranformation Plan(GTP),2010-2015

1. Fertilizer Complex Plant------Capacity 300,000 t0n urea/year

2. Caustic soda Plant:------------ Capacity 50,000 ton/year

3.Soda Ash Plant--------------------Capacity 35,000 ton ton/year

4.Soap and Detergent Plant:-----Capacity 166000 ton ton/year

5.Paper Pulp Plant:------------------Capacity 31 500 ton ton/year

6. Paper plant--------------------------Capacity 41 000 ton ton/year

7. Poly ethylene plant-------------- Capacity35 000 ton ton/year

8.Natural Rubber Latex Plant-----Capacity 6700 ton ton/year

9.Sugar Processing Industries------------------- 12 plants•National capacity will reach 2.25 million tons in2015•Current National capacity about 0.315 million tons(2010)• Production will increase by 1.935 million tons

10. Ethanol Plant•National capacity will reach 304 000 m3 in2015•Current National Production capacity 30 124 m3

(2010)11. Cement Processing Industries

•National capacity will reach 27 million tons in2015•Current National capacity about 3 million tons(2010)

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6.9 PROFESSIONAL REORIENTATIONS of

ETHIOPIAN CHEMICALEeNGINEERS

•Professionals should be re-oriented to go

into the business of chemical production and

marketing. They should come out of their

book world or black box, develop skills to

generate productive technology,become

enterpreneur and start producing marketable

goods

• AIChE

• CSChE

www.aiche.org

www.chemeng.ca

• IChemEwww.icheme.chemeng.ed.ac.uk

• Consult senior Chemical Engineers

• Join the student chapter of ESChE

• Read Chemical Engineering magazines

How do I find out more information

about Chemical Engineering ?

CHEE 2404:Industrial Chemistry 70

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71

Good Luck for

all of You

THANK YOU