# Chemical Engineering - Phase 2 Processes Backlog

## Overview

This document outlines the key processes identified for Phase 2 implementation in the Chemical Engineering specialization. These processes cover the full spectrum of chemical engineering activities from process design and reaction engineering to safety management and sustainability optimization.

## Process Categories

### 1. Process Design and Simulation

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-001 | Process Flow Diagram Development | Create comprehensive PFDs with mass/energy balances, stream tables, and equipment identification for chemical processes | High | Medium |
| CE-002 | Heat Integration Analysis | Apply pinch analysis methodology to optimize heat recovery, design heat exchanger networks, and minimize utility consumption | High | High |
| CE-003 | Process Simulation Model Development | Build and validate steady-state process simulation models using tools like Aspen Plus, HYSYS, or DWSIM | High | High |
| CE-004 | Equipment Sizing and Specification | Size and specify major process equipment including vessels, columns, heat exchangers, pumps, and compressors | High | Medium |

### 2. Reaction Engineering

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-005 | Reactor Design and Selection | Select appropriate reactor type (CSTR, PFR, batch, fluidized bed) and design reactor systems based on kinetics and process requirements | High | High |
| CE-006 | Kinetic Model Development | Develop reaction kinetics models from experimental data, including rate equations, activation energies, and mechanism validation | High | High |
| CE-007 | Catalyst Evaluation and Optimization | Evaluate catalyst options, optimize catalyst loading and operating conditions, and predict catalyst lifetime | Medium | High |
| CE-008 | Scale-Up Analysis | Perform systematic scale-up from laboratory to pilot to production scale, addressing scale-dependent phenomena | High | High |

### 3. Separation Process Engineering

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-009 | Distillation Column Design | Design distillation systems including column sizing, tray/packing selection, and optimization for energy efficiency | High | Medium |
| CE-010 | Membrane Separation System Design | Design membrane-based separation systems including reverse osmosis, ultrafiltration, and pervaporation | Medium | Medium |
| CE-011 | Crystallization Process Design | Design crystallization and precipitation systems for product purification and solid-liquid separation | Medium | High |
| CE-012 | Separation Sequence Synthesis | Develop optimal separation sequences for multi-component mixtures considering energy, cost, and product purity | Medium | High |

### 4. Process Safety Management

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-013 | HAZOP Study Facilitation | Conduct systematic Hazard and Operability studies for new and modified processes with proper documentation | High | High |
| CE-014 | Safety Instrumented System Design | Design safety instrumented systems (SIS) to achieve required Safety Integrity Levels (SIL) per IEC 61511 | High | High |
| CE-015 | Pressure Relief System Design | Size and design pressure relief systems including relief valves, rupture disks, and flare systems per API 520/521 | High | Medium |
| CE-016 | Consequence Analysis | Perform consequence modeling for hazardous releases including dispersion, fire, and explosion scenarios | Medium | High |

### 5. Process Control and Optimization

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-017 | Control Strategy Development | Design process control strategies including control loops, cascade controls, and ratio controls for unit operations | High | Medium |
| CE-018 | PID Controller Tuning | Systematically tune PID controllers using model-based and empirical methods for optimal process performance | Medium | Medium |
| CE-019 | Model Predictive Control Implementation | Design and implement MPC systems for advanced process control and optimization | Medium | High |
| CE-020 | Alarm Rationalization | Review and rationalize process alarms to reduce alarm floods and improve operator response | Medium | Medium |

### 6. Sustainability and Environmental

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-021 | Process Sustainability Assessment | Evaluate process sustainability using green chemistry metrics, life cycle assessment, and environmental impact analysis | High | High |
| CE-022 | Waste Minimization Analysis | Identify opportunities for waste reduction, recycling, and process modification to minimize environmental impact | High | Medium |
| CE-023 | Energy Efficiency Optimization | Analyze and optimize process energy consumption, implement energy management systems, and evaluate renewable integration | High | Medium |

### 7. Project Execution and Commissioning

| ID | Process Name | Description | Priority | Complexity |
|----|--------------|-------------|----------|------------|
| CE-024 | Process Startup Procedure Development | Develop comprehensive startup procedures including pre-startup safety reviews and commissioning protocols | Medium | Medium |
| CE-025 | Performance Testing and Validation | Design and execute performance tests to validate process performance against design specifications | Medium | Medium |

---

## Process Details

### CE-001: Process Flow Diagram Development

**Objective:** Create comprehensive process flow diagrams that serve as the basis for detailed engineering and operations.

**Key Activities:**
- Define process boundaries and battery limits
- Develop material and energy balances
- Identify and size major equipment
- Create stream tables with compositions, flows, temperatures, and pressures
- Specify operating conditions and control points
- Document design assumptions and basis

**Deliverables:**
- Process Flow Diagram (PFD) drawing
- Stream table with all process streams
- Equipment list with preliminary sizing
- Design basis document
- Mass and energy balance summary

**References:** Douglas Conceptual Design methodology, Seider Product and Process Design Principles

---

### CE-002: Heat Integration Analysis

**Objective:** Optimize heat recovery and minimize utility consumption through systematic pinch analysis.

**Key Activities:**
- Extract stream data (hot/cold streams, temperatures, heat capacities)
- Construct composite curves and grand composite curve
- Determine minimum utility requirements (pinch point)
- Design heat exchanger network above and below pinch
- Evaluate heat integration vs. operability trade-offs
- Identify opportunities for process modification

**Deliverables:**
- Stream data extraction table
- Composite curves and pinch analysis results
- Heat exchanger network diagram
- Utility reduction summary
- Economic analysis of heat integration

**References:** Linnhoff pinch analysis methodology, Smith Chemical Process Design and Integration

---

### CE-003: Process Simulation Model Development

**Objective:** Build validated process simulation models for design, optimization, and troubleshooting.

**Key Activities:**
- Select appropriate thermodynamic models
- Configure unit operations and connectivity
- Input feed compositions and operating conditions
- Validate model against experimental or plant data
- Perform sensitivity analysis on key parameters
- Document model assumptions and limitations

**Deliverables:**
- Validated simulation model file
- Model documentation and user guide
- Thermodynamic model selection rationale
- Validation report with comparison to data
- Sensitivity analysis results

**References:** Aspen Plus/HYSYS documentation, Properties of Gases and Liquids (Poling)

---

### CE-004: Equipment Sizing and Specification

**Objective:** Size and specify process equipment for procurement and detailed design.

**Key Activities:**
- Calculate design conditions (pressure, temperature, flow rates)
- Apply design margins and safety factors
- Size equipment using established methods
- Select materials of construction
- Develop equipment specification sheets
- Coordinate with mechanical engineers

**Deliverables:**
- Equipment specification sheets
- Sizing calculations with assumptions
- Material selection rationale
- Vendor data requirements
- P&ID equipment tags and descriptions

**References:** Perry's Chemical Engineers' Handbook, Walas Chemical Process Equipment

---

### CE-005: Reactor Design and Selection

**Objective:** Design reactor systems that achieve required conversion, selectivity, and throughput safely.

**Key Activities:**
- Review reaction chemistry and thermodynamics
- Select reactor type based on kinetics and process requirements
- Size reactor for required conversion and throughput
- Design heat transfer systems for temperature control
- Evaluate mixing and mass transfer requirements
- Assess reactor safety (thermal runaway, pressure relief)

**Deliverables:**
- Reactor type selection rationale
- Reactor sizing calculations
- Heat transfer design
- Operating envelope definition
- Safety assessment summary

**References:** Fogler Elements of Chemical Reaction Engineering, Levenspiel Chemical Reaction Engineering

---

### CE-006: Kinetic Model Development

**Objective:** Develop reaction kinetics models for reactor design, simulation, and optimization.

**Key Activities:**
- Design kinetic experiments using DOE
- Collect reaction rate data at various conditions
- Propose reaction mechanism and rate expressions
- Estimate kinetic parameters through regression
- Validate model over operating range
- Assess model uncertainty and limitations

**Deliverables:**
- Kinetic rate expressions and parameters
- Experimental data summary
- Parameter estimation methodology
- Model validation report
- Applicable operating range documentation

**References:** Froment Chemical Reactor Analysis and Design, DOE methodologies

---

### CE-007: Catalyst Evaluation and Optimization

**Objective:** Select, optimize, and manage catalyst systems for chemical processes.

**Key Activities:**
- Screen candidate catalysts for activity and selectivity
- Optimize catalyst loading and operating conditions
- Characterize catalyst deactivation mechanisms
- Develop catalyst regeneration procedures
- Predict catalyst lifetime and replacement schedules
- Evaluate catalyst cost and supply chain

**Deliverables:**
- Catalyst selection report
- Optimized operating conditions
- Deactivation model and lifetime prediction
- Regeneration procedure (if applicable)
- Catalyst management plan

**References:** Bartholomew Fundamentals of Industrial Catalytic Processes

---

### CE-008: Scale-Up Analysis

**Objective:** Successfully scale processes from laboratory to production while maintaining performance.

**Key Activities:**
- Identify scale-dependent phenomena
- Develop scale-up criteria and dimensionless groups
- Design pilot-scale experiments
- Validate models at intermediate scales
- Address mixing, heat transfer, and mass transfer changes
- Manage scale-up risks through staged approach

**Deliverables:**
- Scale-up methodology and criteria
- Pilot plant design requirements
- Scale-up risk assessment
- Validation test plan
- Technology transfer package

**References:** Scale-up methodologies, dimensionless analysis

---

### CE-009: Distillation Column Design

**Objective:** Design distillation systems that meet separation requirements efficiently.

**Key Activities:**
- Specify product purity and recovery requirements
- Select column configuration (simple, complex, batch)
- Determine minimum stages and reflux ratio
- Size column diameter and height
- Select internals (trays or packing type)
- Optimize for energy efficiency

**Deliverables:**
- Column specification sheet
- McCabe-Thiele or rigorous simulation results
- Internal selection rationale
- Energy consumption analysis
- Operating procedures for startup

**References:** Kister Distillation Design, Seader Separation Process Principles

---

### CE-010: Membrane Separation System Design

**Objective:** Design membrane-based separation systems for appropriate applications.

**Key Activities:**
- Evaluate membrane applicability for separation
- Select membrane type and material
- Design module configuration
- Calculate membrane area and staging
- Specify operating conditions and pretreatment
- Plan membrane replacement and cleaning

**Deliverables:**
- Membrane selection rationale
- System design with staging
- Operating procedure
- Fouling management plan
- Economic comparison with alternatives

**References:** Mulder Basic Principles of Membrane Technology

---

### CE-011: Crystallization Process Design

**Objective:** Design crystallization systems for product purification and solid recovery.

**Key Activities:**
- Characterize solubility and metastable zone
- Select crystallization method (cooling, evaporative, anti-solvent)
- Design crystallizer equipment
- Control crystal size distribution
- Design solid-liquid separation downstream
- Address polymorphism and purity requirements

**Deliverables:**
- Solubility data and phase diagram
- Crystallizer design and sizing
- Operating procedure for crystal quality
- Downstream separation design
- Product purity validation plan

**References:** Crystallization fundamentals, pharmaceutical crystallization guidelines

---

### CE-012: Separation Sequence Synthesis

**Objective:** Develop optimal separation sequences for multi-component mixtures.

**Key Activities:**
- Characterize mixture components and properties
- Identify potential separation methods
- Generate alternative sequences
- Screen alternatives using heuristics
- Optimize promising sequences
- Consider heat integration opportunities

**Deliverables:**
- Mixture characterization
- Alternative sequence analysis
- Optimized sequence recommendation
- Energy and cost comparison
- Heat integration opportunities

**References:** Douglas hierarchy, separation synthesis heuristics

---

### CE-013: HAZOP Study Facilitation

**Objective:** Conduct systematic hazard identification and risk assessment for chemical processes.

**Key Activities:**
- Define study scope and objectives
- Assemble multi-disciplinary team
- Review P&IDs systematically using guidewords
- Identify deviations, causes, and consequences
- Evaluate existing safeguards
- Recommend additional safeguards
- Document findings and follow actions

**Deliverables:**
- HAZOP study report
- Action items with responsibilities
- Updated P&IDs with safeguards
- Risk register updates
- Recommendations for design changes

**References:** CCPS Guidelines for Hazard Evaluation Procedures, IChemE HAZOP Guide

---

### CE-014: Safety Instrumented System Design

**Objective:** Design SIS to achieve required risk reduction and meet IEC 61511.

**Key Activities:**
- Identify safety instrumented functions (SIF)
- Determine required SIL for each SIF
- Select SIS architecture and components
- Calculate achieved SIL through reliability analysis
- Design for diagnostics and testing
- Develop SIS validation test plan

**Deliverables:**
- Safety Requirements Specification (SRS)
- SIL determination documentation
- SIS architecture design
- SIL verification calculations
- Validation test procedures

**References:** IEC 61511, ISA 84.00.01, CCPS SIS guidelines

---

### CE-015: Pressure Relief System Design

**Objective:** Design pressure relief systems to protect equipment and personnel.

**Key Activities:**
- Identify relief scenarios (fire, blocked outlet, runaway)
- Calculate required relief rates
- Select relief device type (PSV, rupture disk)
- Size relief devices per API 520
- Design relief header and disposal system
- Verify installation per API 521

**Deliverables:**
- Relief scenario documentation
- Relief device sizing calculations
- Relief system P&ID
- Disposal system design
- Relief device specification sheets

**References:** API 520, API 521, DIERS methodology for reactive systems

---

### CE-016: Consequence Analysis

**Objective:** Model consequences of hazardous releases for risk assessment and emergency planning.

**Key Activities:**
- Define release scenarios
- Model source term (release rate, duration)
- Perform dispersion modeling
- Model fire and explosion effects
- Determine impact zones
- Develop emergency response zones

**Deliverables:**
- Release scenario definitions
- Dispersion modeling results
- Fire/explosion effect distances
- Impact zone maps
- Emergency response planning input

**References:** PHAST/ALOHA tools, CCPS QRA guidelines

---

### CE-017: Control Strategy Development

**Objective:** Design process control strategies for stable and efficient operation.

**Key Activities:**
- Define control objectives
- Identify controlled and manipulated variables
- Select control structure (feedback, feedforward, cascade)
- Design control loops for unit operations
- Address process interactions and constraints
- Document control philosophy

**Deliverables:**
- Control philosophy document
- Control loop diagrams
- P&ID control annotations
- Setpoint and tuning guidelines
- DCS configuration specification

**References:** Seborg Process Dynamics and Control, Stephanopoulos Chemical Process Control

---

### CE-018: PID Controller Tuning

**Objective:** Tune controllers for optimal process response and stability.

**Key Activities:**
- Identify process dynamics (dead time, time constant)
- Select tuning method (Ziegler-Nichols, IMC, relay)
- Calculate initial tuning parameters
- Implement and test tuning
- Fine-tune for robustness
- Document final parameters

**Deliverables:**
- Process dynamic characterization
- Tuning parameter calculations
- Implementation results
- Final tuning parameters
- Performance metrics

**References:** Controller tuning methods, Marlin Process Control

---

### CE-019: Model Predictive Control Implementation

**Objective:** Implement MPC for advanced process optimization and constraint handling.

**Key Activities:**
- Identify MPC candidates and benefits
- Develop process dynamic models
- Configure MPC controller
- Tune prediction and control horizons
- Commission and validate performance
- Train operators on MPC operation

**Deliverables:**
- MPC scope and benefit analysis
- Dynamic model documentation
- MPC configuration
- Commissioning report
- Operator training materials

**References:** Qin MPC survey paper, AspenTech DMC documentation

---

### CE-020: Alarm Rationalization

**Objective:** Optimize alarm system to reduce alarm floods and improve operator response.

**Key Activities:**
- Inventory existing alarms
- Classify alarms by priority and consequence
- Remove nuisance alarms
- Optimize setpoints and deadbands
- Design alarm response procedures
- Implement alarm management system

**Deliverables:**
- Alarm rationalization database
- Updated alarm settings
- Alarm response procedures
- Alarm performance metrics
- Ongoing management plan

**References:** ISA-18.2 Alarm Management Standard, EEMUA 191

---

### CE-021: Process Sustainability Assessment

**Objective:** Evaluate and improve process sustainability using systematic methods.

**Key Activities:**
- Define system boundaries and functional unit
- Calculate green chemistry metrics (E-factor, atom economy)
- Perform life cycle assessment
- Identify environmental hotspots
- Develop improvement options
- Quantify sustainability improvements

**Deliverables:**
- Sustainability metrics baseline
- Life cycle assessment results
- Environmental impact summary
- Improvement recommendations
- Implementation roadmap

**References:** Anastas Green Chemistry, Allen Green Engineering

---

### CE-022: Waste Minimization Analysis

**Objective:** Identify and implement opportunities to minimize waste generation.

**Key Activities:**
- Characterize waste streams
- Apply waste minimization hierarchy
- Identify source reduction opportunities
- Evaluate recycling and recovery options
- Assess treatment requirements
- Develop implementation plan

**Deliverables:**
- Waste stream inventory
- Minimization opportunity assessment
- Recommended actions
- Economic analysis
- Regulatory compliance review

**References:** EPA waste minimization guides, pollution prevention hierarchy

---

### CE-023: Energy Efficiency Optimization

**Objective:** Optimize process energy consumption and evaluate efficiency improvements.

**Key Activities:**
- Conduct energy audit
- Identify energy consumption by unit operation
- Apply pinch analysis and heat integration
- Evaluate efficiency improvements
- Assess renewable energy integration
- Develop energy management plan

**Deliverables:**
- Energy audit report
- Heat integration analysis
- Improvement recommendations
- Economic analysis
- Energy management KPIs

**References:** Klemes Process Integration, energy audit methodologies

---

### CE-024: Process Startup Procedure Development

**Objective:** Develop comprehensive procedures for safe and efficient process startup.

**Key Activities:**
- Define startup sequence and milestones
- Identify pre-startup safety review items
- Develop detailed operating procedures
- Define startup parameters and limits
- Plan staffing and training
- Prepare for startup troubleshooting

**Deliverables:**
- Startup procedure document
- PSSR checklist
- Operator training plan
- Startup timeline
- Troubleshooting guide

**References:** CCPS startup safety, OSHA PSM requirements

---

### CE-025: Performance Testing and Validation

**Objective:** Validate process performance against design specifications.

**Key Activities:**
- Define performance test objectives
- Develop test protocol
- Prepare instrumentation and data collection
- Execute performance tests
- Analyze results vs. specifications
- Document performance guarantees

**Deliverables:**
- Test protocol
- Data collection package
- Test results analysis
- Performance certificate
- Recommendations for optimization

**References:** Performance testing standards, process validation guidelines

---

## Implementation Priority Matrix

| Priority | Process IDs | Rationale |
|----------|-------------|-----------|
| High | CE-001, CE-002, CE-003, CE-004, CE-005, CE-006, CE-008, CE-009, CE-013, CE-014, CE-015, CE-017, CE-021, CE-022, CE-023 | Core chemical engineering processes with high impact on safety, quality, and economics |
| Medium | CE-007, CE-010, CE-011, CE-012, CE-016, CE-018, CE-019, CE-020, CE-024, CE-025 | Important processes that support primary activities and optimization |

## Dependencies

```
CE-003 (Simulation) --> CE-001 (PFD) --> CE-004 (Equipment Sizing)
                    --> CE-002 (Heat Integration)
                    --> CE-009 (Distillation Design)

CE-006 (Kinetics) --> CE-005 (Reactor Design) --> CE-008 (Scale-Up)
                  --> CE-007 (Catalyst Optimization)

CE-013 (HAZOP) --> CE-014 (SIS Design)
              --> CE-015 (Relief System)
              --> CE-016 (Consequence Analysis)

CE-017 (Control Strategy) --> CE-018 (PID Tuning)
                          --> CE-019 (MPC)
                          --> CE-020 (Alarm Rationalization)

CE-001 (PFD) --> CE-021 (Sustainability)
            --> CE-022 (Waste Minimization)
            --> CE-023 (Energy Efficiency)
```

## Success Metrics

| Category | Metric | Target |
|----------|--------|--------|
| Process Design | PFD development cycle time | < 2 weeks |
| Process Design | Simulation model accuracy | > 95% vs. plant data |
| Reaction Engineering | Scale-up success rate | > 90% first-time success |
| Separation | Energy consumption vs. benchmark | < 110% of minimum |
| Safety | HAZOP completion rate | 100% before startup |
| Safety | SIL verification pass rate | 100% SIF meet target |
| Control | Controller in auto rate | > 95% |
| Sustainability | Waste reduction vs. baseline | > 20% reduction |

## Resource Requirements

- **Process Engineers:** Lead process design, simulation, and optimization activities
- **Reaction Engineers:** Lead reactor design and kinetic modeling
- **Safety Engineers:** Lead HAZOP, SIS design, and consequence analysis
- **Control Engineers:** Lead control strategy and advanced control implementation
- **Project Engineers:** Coordinate execution and commissioning activities
- **Software Tools:** Aspen Plus/HYSYS, PHAST/ALOHA, DCS platforms, MPC software

## References

See [references.md](./references.md) for comprehensive list of standards, textbooks, and resources supporting these processes.
