Chemical Engineering Capstone Project on Process Optimization

Chemical engineering capstone projects that focus on process optimization aim to improve the efficiency, cost-effectiveness, and sustainability of industrial processes. Process optimization in chemical engineering involves enhancing systems to minimize waste, reduce energy consumption, and improve product yield, all while maintaining safety and regulatory standards.

Project Concept

A potential chemical engineering capstone project could involve optimizing a chemical production process, such as the manufacturing of biofuels, pharmaceuticals, or industrial chemicals. The focus could be on improving the overall efficiency of a process by reducing energy use, increasing throughput, or improving the quality of the product. Alternatively, the project could focus on waste minimization, optimizing the use of raw materials, or improving waste treatment in the production process.

Design Process

The design phase starts with analyzing the current chemical process in its entirety. This includes mapping the entire process flow, identifying key input and output variables, and pinpointing inefficiencies or bottlenecks. Students may use software tools like Aspen Plus, HYSYS, or MATLAB to simulate the chemical process, assess the mass and energy balances, and evaluate the existing operations.

Optimization Techniques

The optimization techniques could involve applying methods such as:

• Linear programming (LP): To optimize resource allocation and minimize costs.
• Statistical Process Control (SPC): To monitor and control the variability of processes, ensuring product quality and consistency.
• Sensitivity Analysis: To understand how changes in different variables affect the process and to determine the most influential factors in improving performance.

Testing and Implementation

Once the optimization methods have been identified, students would propose modifications to the existing process. The modifications could include adjusting operational parameters, adding new technologies (e.g., energy recovery systems), or redesigning certain aspects of the process. A pilot-scale test or simulation is typically carried out to validate the proposed improvements.

Final Report and Conclusion

The final report would present the original process analysis, the proposed changes, and the results of the optimization efforts. It should also include cost-benefit analysis, sustainability considerations, and suggestions for future improvements. By the end of the project, students should demonstrate that their optimizations provide tangible improvements in process efficiency, cost reduction, and environmental sustainability.