In this blog post, learn how chemical engineers design and optimize processes to maximize profits for companies.

Department of Chemical and Biomolecular Engineering

If you were to draw a mind map with the word chemical engineering, what would the map look like? Refineries, chemical plants, petrochemicals, polymers, and more. When we think of chemical engineering, we usually think of the process of refining imported crude oil to produce diesel, kerosene, gasoline, naphtha, etc. and the process of using naphtha from crude oil refining to produce plastic polymer products. However, the words plant design and the complex processes involved in producing these products probably don’t come to mind.

What is the plant industry and why is it important

The plant industry refers to industries that provide equipment or build plants to produce various products such as electricity, oil, gas, fresh water, etc. Chemical engineering is the study of not only the production of products, but also how to organize the processes and plants to produce those products in the most efficient and profitable way possible. Plant design aims to reduce costs and achieve high productivity through optimized processes.

Maximizing profits and minimizing costs

One of the most important values in engineering is profit. Making the most profit at the lowest possible cost is one of the biggest goals of any company when it comes to producing a product. Chemical engineers study and review the feasibility, financing, design, purchasing, construction, and commissioning of a project to optimize this process. For example, if Company A wants to build a plant to produce a certain product, but does not have the capacity to design and build such a facility in-house, Company B, which specializes in this field, will build the plant for them.
This process can range from day-to-day factory construction to huge cross-border projects. For example, in 2009, the Lee Myung-bak government and a consortium of Korean power companies won a $20 billion order from the UAE to build a nuclear power plant. The project involved the UAE paying a Korean company $20 billion to build a nuclear power plant, and the Korean company building the plant in return. In such large-scale projects, cost reduction and profit maximization are crucial, and the expertise of chemical engineers is essential in this process.

Components of a plant and the design process

The components that make up a plant can be likened to Lego pieces. Reactors used to carry out chemical reactions, heat exchangers for cooling or heating, pumps that use pressure to move fluids, valves to regulate the amount and pressure of fluids, and many other units are the result of a combination of mechanical, electrical, and architectural engineering elements. Chemical engineers are responsible for deciding which of these LEGO pieces to choose, how to assemble them, and even designing the chemical reactions that will take place in the finished block.
The number of cases in which the type of LEGO pieces and the order in which they are placed are countless. The key role of a chemical engineer is to identify and design the combinations that will allow for optimal production from these endless possibilities. For example, the efficiency and cost structure of a plant can vary significantly depending on which reactors and heat exchangers are used to produce the same product.

The need for optimization and the role of the chemical engineer

Plant design is not just about producing a product. In addition to minimizing the cost of raw materials and energy used to produce the product, optimizing the placement and configuration of the reactors, heat exchangers, pumps, valves, etc. that make up the plant is essential to maximizing profitability. For example, optimizing the design of a heat exchanger to increase energy efficiency or improving the way catalysts are utilized within a reactor can dramatically reduce production costs and maximize profit margins.
With such large-scale and costly undertakings, chemical engineers are required to have a high level of expertise in the design process, as well as the responsibility and problem-solving skills to address unforeseen issues as they arise. For example, large plants, such as nuclear power plants, operate for decades, so even small errors in the initial design can lead to large economic losses.

Plant operations and sustainable development

Another important factor in designing and operating a plant is environmental sustainability. In recent years, it has become increasingly important to design plants not just to maximize profits, but also to protect the environment and aim for sustainable development. As such, chemical engineers must find technical solutions to minimize energy consumption, reduce waste, and reduce greenhouse gas emissions during the process.
For example, many companies have recently adopted various technologies to reduce carbon emissions. Examples include carbon capture and storage (CCS) technologies that capture and store carbon dioxide from plants, process designs that utilize renewable energy, and circulation systems that reduce water consumption. By effectively implementing these technologies, companies can realize long-term cost savings and sustainable operations.

Conclusion

Chemical engineers are more than just technicians who produce products; they play an important role in maximizing corporate profits through optimal processes and designs, and in achieving sustainable development. Their expertise and responsibility in plant design and operation is essential, enabling companies to realize more efficient and economical production. The role of chemical engineers will become increasingly important in the future, and the innovative designs and technologies they create will have a positive impact on our industries and the environment.