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New Vistas for Process Systems Engineering: Integrating Physics

Computation and Communication Networks for Better Decision Making New Frontiers in Chemical Engineering: Impact on Undergraduate Curriculum Workshop, WPI May 7, 2004

The Context (Industry/University/Grad. Research) Challenges in UG graduation (Curriculum/Constraints/Proposal) PSE Research (Case studies/Challenge)

B. Erik Ydstie Carnegie Mellon University

The Context: The Industries we Serve

Pittsburgh: Steel, Aluminum, Glass ++.

What about: PetroChemicals? Micro-Electronics Manufacture? Software? - What about Bio/Med-technology? Research and Development? ++

Local Protected*

Global, Flexible Market Oriented

* Proprietary technology, transportation, trade barriers, technology gap, know how,…

The Context: The University

Specialization (“Excellence”) and the Student as Customer

Local/National Canonical Programs Fixed curriculum

Global, Market oriented Student choice, many options Flexible curriculum

CMU: $40M Univ Center. $40M Performing Arts. Programs in Greece/Calif./Quatar

Mission Statement: A Carnegie Mellon education aims to prepare students for life and leadership. In a continually changing world, the most important qualities we can help our students develop are the ability to think independently and critically, the ability to learn, and the ability to change and grow.

Context: University Graduate Research

Chem. E. Research Programs have moved into new technologies and application areas. Dynamic and exciting! New Courses are being developed.

* Beyond the Molecular Frontier, CST-NRC Report, NAE/NAS, 2003 Sessions at recent AIChE meetings

Large scale computation, complex networks, molecular dynamics and design, quantum mech Biological systems theory, micro-electronics, complex fluids, self-assembly nano technology,…*

Unit Process Design and control, petro-chemical processes, analytic and graphical solution to, transport, thermo, fluids and staged separation prblms,+++

Chem Eng Curriculum: “The Pipeline Model”

Static for 30+yrs

+ Basic Science and Math Gen. Ed., Tech Elect., Minors/Majors.

1st year: Intro Chem Eng 12 2nd year: Thermo 1 9 Fluid Mechanics 9 Math Methods of Chem. Eng. 12 3rd year: Thermo 2 9 Heat and Mass 9 Unit Operations 9 Transport Lab 6 Process Control 9 4th year Process Design 12 Reaction Engineering 9 Unit Ops Lab 9 Design Project/Optimization 12

Curriculum

Intro to ChemE

Class of 2004

http://www.cheme.cmu.edu/

Lab

Lab

Control

Product Development

Process Engineering

Seminar

Thermo

ChemE Math

Fluid Mech

ChemE Thermo

Heat & Mass

Seminar

Rxn Eng

Unit Ops

Process Design

Design Project

Econ & Optim

The Result: Where Do CMU ChE Students go to Work

Motorola IBM Seagate Motorola Xerox Samsung Austin Semiconductor Intel Aspen Technology Ethicon Aquatech Cytec Photocircuits Corp International Fuel Cells. Lexmark International Andersen Consulting Goldman Sachs Deloitte and Touche American Management Systems Fuji Capital Markets Banc of America Securities Putnam Investments Accenture Americore High Scool Education Grad Schools

BOC Gases Air Liquide Air Products & Chemicals duPont Dow Chemical Exxon Mobil Kodak General Electric Corning Bristol-Myers Squibb Merck Pharmacia Procter & Gamble Johnson & Johnson L'Oreal U.S. Steel PPG Westinghouse DOE Navy National Institute for Drug Abuse

Major Trends in Chemical Engineering: Increased diversity of jobs for

chemical engineers

40% chemicals/fuels

32% chemicals/fuels

B.Sc. Placement AIChE (2001)

Ph.D. Placement AIChE (2001)

Mid-Course Conclusions:

Universities: Flexible, Market Oriented. Chemical Industry: same (new products/processes) Grad Research: same (new areas bio/nano,..) Students: same (diverse employment) UG ChE Curr: Static (“one size fits all”)

Why are ChE’s so adaptable? Can we improve curriculum? Make ChE relevant and attractive for high school students (what do Chem. E.s do?).

-the best and the brightest are unlikely to choose chemical engineering in anything like the same numbers as in the past, and government and probably industrial funding will decline. Prof. Herb Toor, (frmr.) Dean of Engineering CMU.

Why are Chem E’s adaptable

Can we/Should we improve curriculum

What do Chem. E.s do (we are judget by the product)

Must re-think our petrochemical (vap/liq.) focus

petrochemical industry. research/teaching/government finance/consulting high tech software pharmaceutical/health care consumer products develop new materials environmental

Broad base in science, analysis and engineering. Systems thinking promoted in control and design. Attracts a special kind of student.

Yes

Constraints to Change 1: ABET and AIChE

PROGRAM CRITERIA FOR CHEMICALAND SIMILARLY NAMED ENGINEERING PROGRAMS (ABET) Lead Society: American Institute of Chemical Engineers Curriculum: The program must demonstrate that graduates have: thorough grounding in chemistry and a working knowledge of advanced chemistry such as organic, inorganic, physical, analytical, materials chemistry, or biochemistry, selected as appropriate to the goals of the program; and working knowledge, including safety and environmental aspects, of material and energy balances applied to chemical processes; thermodynamics of physical and chemical equilibria; heat, mass, and momentum transfer; chemical reaction engineering; continuous and stage-wise separation operations; process dynamics and control; process design; and appropriate modern experimental and computing techniques.

Constraints to Change 2: The Textbooks

Fact: Easy to teach and learn when there is a good book.

The quality of the books range from superb to excellent. But -

Process Control (Stephanopolous, Seborg et al., Bequette,.. Fluid Mechanics (3*W, BSL) Thermodynamics 1&2, (Smith and Van Naess, Sandler,… Process Design (Douglas, Grossmann, … Chem E Math (Kreyzig, diPrima,…

Contents (examples) too much focused on “ideal” vap/liq systems. A lot of time spent to develop analytical/graphical solution methods. The lead time from new research and technology to UG instruction can be very long.

The Example of Process Control

Typical Course Contents:

Theory:

Application:

Introduces students to Dynamics and Systems Thinking

Dynamic Models Laplace Transforms Block Diagrams Stability Controller Design and tuning PID control Feedforward IMC Decoupling Relative Gain Array Predictive Control

Tanks Reactors Distillation Bio-control Batch Control Plantwide control

What can be Done

Enablers:

Desired Situation:

Current Situation:

Plan:

Academic freedom Engaged faculty Graduate research and courses Industrial involvement in R&D University backing --

Dynamic curriculum. Based on the “engineering science and analysis”. Technologies of current interest(bio/enviro/ molecular/petro-chem,…)

Static curriculum. Based on “engineering science and analysis” . Weighted towards petro-chemicals (Cap-stone design).

Review science core (now). Introduce “selectives” (now). Hire faculty in key areas. Develop new courses. New textbooks.

Modest Proposal: Non-Uniform Curriculum

Core: (All Chem. E.’s, Backed up by Labs*) Math/Analysis/Computation (Thermo 1 and 2?) Chemistry/Bio Chemistry Reaction Engineering Heat/Mass/Momentum Transport (Unit Operations? Process Control? Process Design 1,2,3?) Process Systems Engineering

Selectives: (Choose N out of following) Semiconductor processing Atmospheric Chemistry Air Pollution and Global Change Bio Technology and Environmental Processes Bio Process Design Principles and Application of Molecular Simulation Physical Chemistry of Macro Molecules Advanced Process Systems Engineering

Computer Labs w. Adv. Software (CFD, Process Design, Math, Control,…) Physical Labs (measurement, analysis, process, procedure..)

Process Systems Engineering: See the BIG Picture in the Small Pieces

Finding the right piece and seeing how it fits is the key. Many may look attractive, but they may not answer to our current needs.

PSE Research: Integrating Physics and Computation

New application Domains

Better computation and communication tools

New Software and algorithms

Vitality as Focus Shifts from Methods to Applications

Bio tech/med (modeling control, optimization) Nano, self assembly, micro-structure Micro electronic processing Business decision making (PSE 2003) Environment and energy.

Parallel distributed processing Effect of “Moore’s law” Data storage and the web

Optimization (SQP/MILP/MINLP… Control (Nonlinear, predictive, hybrid,…

Case Study 1: Carbothermic Aluminum Production (ALCOA Inc

$24B, Aluminum)

Competing processes:

Objective: Develop a better way (less energy and capital cost) for making Aluminum.

Pre-bake Pechiney FR

Hall-Heroult Al2O3+ C = Al + CO2 Inert Anode Al2O3 = Al+ O2 Carbothermic Al2O3+ C = Al + CO

Soederberg KrSand No

Hall Cell Pgh PA

PSE Contribution: Multi-scale Modeling (Integrate Physics and

Computation for Concurrent Design - From Microstructure to Design and Control)

Complex Multi-Physics CFD models Process optimization/control

Case Study 2: Automotive Windshield Manufacture (PPG Inc

$20B, glass, coatings, chemicals)

Supply Chain

OEM - plant

Objective: Control Geometry and Optical Quality of Finished Product. Improve yield, rate and reduce inventory

High vacuum CVD coating

Architectural Glass

8 flat glass plants

6 windshield lines

Automotive Manufacture BMW, Ford, GM, Mercedes,..

laminating

duPont

Finished Product Inventory

Raw Material Inventory

Intermediate Inventory

Finished Product Inventory

Scalable Information Management: Compression, Representation, Modeling

Control Optimization

Information in relation to physical model, business model application model. Adapted to end user Specification Appearance Contents Financial transactions Inventory Physical flow Payroll Plant data (T,P,C,..) ….

Results from On Line Trial: Flat Glass Furnace Control

Advanced control gives competitive advantage. (Differentiation and ability to bid on and negotiate new contracts). High Management Visibility!!!

5% Higher Production rate in OEM: Defect density 75% lower Yield 8% higher

10% Higher Yield in Flat Glass Plant Shorter Changeover time Improve process capability to produce new products Improve process consistency

Case Study 3: New Process and Product

Mergers and Acquisitions (Elkem ASA $3B, Materials)

Limited resources

Objective: Grow Company and and expand product portfolio.

5

6

3

4

7

2

1

8

FeSi, Si, Al, C,SiO2 commodities

Organizational, technological, market, environment, human factors, legal, IP, culture, …

Si, SoG-Si, Al Products Advanced Materials and high value added products

Existing Market New Market

New Process Existing Process

Existing Product New Product

The Systems Approach to Organisation

Result: Significant Change in Product Portfolio. Higher Debt-Equity Ratio

Buy Carbon Plant China Shut Down Plant in Norway Buy Si Plant in Brazil Revamp Alloy Plant Large Scale Si Production in Salten Buy Aluminum Finished Products (SAPA) Secure energy supply through 2020

Technology (PSE) issues

Silicon market

Geography/transporation/cost

Supply chain

Industrial R&D Reflects Company Structure

Decentralized and flexible market driven Expertize brought in as needed

Centralized, Science Driven In-house expertize

New Architecture for Industrial R&D

Strategic Business Units’s (SBU) focus on projects with clear business impact in the areas of process and product improvements Central R&D focus on growth, breakthrough technology and long term sustainability for the company. Involved in strategic decision making, mergers and acquisitions.

Director of Corporate R&D

Business Unit

Business Unit

CTO/VP R&D

Process Control

Aluminum

R&D

R&D

Corporate R&D

Improve Product and Process

Growth and new business

Silicon

Technical IT

Case Study 4: New Process and Product Solar Grade Silicon (REC SGS Ltd

$100M, Si, Wafers, Cells)

Objective: Develop a Cost effective way to make Solar Grade Silicon.

Many companies And technologies compete

PSE helps Concurrent Engineering: New Product and Process

Pilot Demonstration Production

Prospect of reducing cost of producing PV electricity by a factor of 2-3 over the next five years looks promising.

R&D Team: SGS, PE Toronto, CAPD - CMU

Integrated Design to meet or exceed business expectations.

Particulate process Fluidization CFD Multi-scale modeling Optimization Process Design Process Control New Sensors

The PSE Challenges and Opportunities in Research and Education (UG and

Graduate)

Provide theoretical foundation, computational tools, educational methods and skilled personnel for: 1) Designing and operating real time decision support systems for investment (management). These systems comprise physical processes, services, organizations and financial instruments. (High Level Systems Thinking, Architecture design.) 2) Automation of routine decision making in design and operation of complex networks of embedded devices for production and service. Optimization Design Control (Algorithms, methods. Computation) 3) Help advancing the frontiers of chemical engineering research in the application of computational tools to bio tech/bio med/nano tech/molecular, materials and drug design through interdisciplinary research. (Expertise, Algorithms and Methods, Computational insight)

The Challenge:

Faculty, Curriculum

u

y

UG Chem. E. Education

Changing

Changing

Reputation at Large

What goes out? More efficient?

Derive a flexible curriculum that supports the complexity of the current market and adapts as the markets and technologies change.

Envourage High School teaching as a career. Quality and quantity. Core+specialization Include Bio in core

High School Graduates

College Graduates