Experience Sharing in Chemical Process and Control
Thread Content
I have been working in the dry chemical industry for 10 years; I have led teams, supervised commissioning processes, and been responsible for material procurement and coordination. Here, I would like to share some experiences related to chemical processes and control, so that we can all learn from each other. The first topic is the turbine – something that most chemical plants don’t use, and many people may not even be familiar with it. It is more commonly used in water resources and hydropower projects. Its main function is to utilize the remaining pressure of returned water, making it suitable for use in cooling towers, that is, in circulating water systems. In China, Nanjing Xingfei is a well-known company that specializes in turbines. If the water pressure provided by the circulating water system is high and the head of the returned water is significant, then using a turbine could be an option; this would allow us to eliminate the need for a motor to drive the fans in the cooling tower. When I led teams, I had them calculate the power required by the motors as well as the amount of electricity that could be saved. By knowing the air volume, air pressure, and fan efficiency, we can calculate the fan’s power using the formula: N = (Q/3600) * △P / (1000 * η) * K. In fact, this is how the power of most fans is calculated. Understanding such basic energy calculations should be the first skill that novice engineers need to possess :)
Thank you for sharing your experience in chemical processes and control; this is very useful for those working in the chemical industry. Although turbines are not very common in chemical plants, it is still important to understand their principles and uses. Furthermore, it is also very beneficial for energy conservation and emission reduction. Calculating fan power is also a very practical skill; mastering this ability can help us optimize the selection, design, and use of fans. Thank you for sharing! -
It seems like this formula isn’t very useful; the electrical power of the fan is a parameter that is easier to determine compared to air volume, air pressure, and fan efficiency
Don’t think that way; many factories don’t even know how to choose a motor, and the design institutes don’t conduct any calculations either. As a result, in many cases the motors end up not being strong enough to handle the load
Truly, it marks the beginning of a career as a chemical engineer
It’s not really a big deal; this is just the beginning for chemical engineers, with the turbine used as an example to introduce the topic
Yes, you are absolutely right. These basic computing and calculation skills are essential in the work of chemical engineers, and in practice they help us solve problems quickly and improve efficiency. At the same time, I am also very grateful for you sharing these experiences and skills from your work; they are extremely helpful for beginners as well as those working in related fields. I hope you will continue to share more knowledge and practical experience in chemical engineering, so as to jointly promote the development and progress of the industry. -
Before writing about the second topic, I have divided what I consider to be the progression paths for chemical engineers into several stages； Those with different opinions can discuss it: In the first stage, a simple calculation is carried out, taking into account the motor power, pump flow rate, speed, head, as well as the pipelines related to the speed; the simple Bernoulli equation is utilized ； In the second phase, flow velocity and flow field analysis are carried out; the Bernoulli equation is used skillfully to perform calculations such as those related to flow velocity at orifices, throttling control, and resistance assessment ； In the third stage, process energy analysis, phase diagrams are used to examine mass transfer, heat transfer, and energy transfer during phase changes, while relevant energy equations are employed to analyze the inhibitory and facilitating effects in the process ； In the fourth stage, one truly understands the principles of \"three transfers and one reaction\" in chemical engineering, masters the relevant methods for these processes, is able to analyze the factors that affect them, knows how to select appropriate static and dynamic equipment, and develops preliminary skills in systematic analysis ； In the fifth stage, one gains an understanding of and proficiency in the logic of chemical process control, and is able to independently carry out calculations for the automatic control interlock systems of large-scale plant equipment. The relevant auxiliary software truly functions as such – it can verify the calculation processes carried out by Aspen software, and even handle design tasks that cannot be simulated by Aspen ； In the sixth phase, going deeper into the level of reaction mechanisms, corresponding reactors, equipment, etc. are designed, along with the capability for comprehensive system imaging and analysis.
Thank you very much for sharing these stages for the advancement of chemical engineers; they are extremely useful and help beginners as well as those working in this field to better understand their career development paths and goals. Each stage requires its own set of skills and knowledge to master; continuous learning, practice, and improvement are necessary in order to reach a higher level and achieve better results. At the same time, it is also important to combine practice with theory, applying what has been learned to real-world problems in order to continuously improve one’s ability to solve issues. Thank you again for sharing! -
Just starting out in this field, I can only say thank you