How to be a good chemical process engineer

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I. First, it is necessary to clarify the responsibilities of a chemical process engineer: 1. Responsible for providing technical guidance on on-site process operations, ensuring the normal operation of production, and improving production efficiency. 2. Responsible for technical upgrades and the drafting of technical research and development plans. 3. Participate in the investigation and analysis of chemical industry accidents, and develop process improvement measures. 4. Participate in the safety risk assessment of equipment, the identification of safety hazards, as well as the formulation and implementation of process improvement plans. 5. Responsible for the technical training of chemical operators. 6. Responsible for the management of internal process and technical archives. 7. The lead contact person for technical coordination with the design party in chemical construction projects. 8. Participate in the total quality management of the workshop and guide the activities of the team QC groups. 9. Responsible for drafting and formulating technical documents such as process operation procedures, start-up and shutdown technical plans, and process technology management regulations. 10. Responsible for coordinating and communicating with the instrumentation automation team. 11. Assist the workshop process director in management. II. To accomplish the above tasks, what knowledge, skills, and qualities do process engineers need to possess: 1. Basic technical expertise (the fundamental knowledge and skills required to solve problems). l Inorganic Chemistry and Organic Chemistry: These two courses focus on the chemical composition, properties, structure, and reaction mechanisms of inorganic and organic substances, and they constitute the most fundamental knowledge base for the entire chemical industry. All editions of university textbooks can be read for study*. Physical chemistry: A discipline that, based on physical principles and experimental techniques, studies the properties and behavior of chemical systems, and discovers and establishes specific laws governing these systems. In other words, it involves analyzing from a physical perspective the principles, laws, and methods governing the chemical behavior of material systems, and exploring the fundamental laws of chemical reactions by examining the interconnections between physical and chemical phenomena. l Chemical thermodynamics: It primarily studies the energy changes that occur during the physical and chemical transformations of material systems under various conditions, thereby enabling accurate determination of the direction and extent of chemical reactions. Introduce three core theories: energy is conserved, energy conversion ； Things spontaneously tend toward a state of equilibrium ； A material system in equilibrium has a descriptive set of observables. l Chemical Engineering Thermodynamics: Chemical engineering thermodynamics is based on chemical thermodynamics and engineering thermodynamics. It primarily studies the laws governing the mutual conversion of various forms of energy in chemical processes, as well as the limiting conditions for process equilibrium. It provides a theoretical basis for the efficient utilization of energy and the improvement of actual processes. The classic textbook is, of course, \"Thermodynamics of Chemical Engineering\" by B.F. Dodge, a professor at Yale University in the United States. Physical chemistry, chemical thermodynamics, and chemical engineering thermodynamics are the fundamental knowledge courses for performing calculations in chemical engineering thermodynamics and chemical kinetics in work. 2. Professional technical applications in engineering – Principles of chemistry: Based on the fundamental theories of momentum transfer, heat transfer, and mass transfer, it explains the basic principles of unit operations such as fluid transport, sedimentation, filtration, heat transfer, absorption, distillation, and drying, as well as the structure of typical equipment, process calculations, equipment selection, and experimental research methods. Recommended study material: The university textbook \"Principles of Chemical Engineering\" written by Wang Zhikui and published by the Chemical Industry Publishing House. l Chemical Process Engineering: A textbook that covers the development of production processes for chemical products such as synthetic ammonia and sulfuric acid, their preparation principles, production characteristics, process flows, and key equipment; students can choose the content to study based on their area of specialization. l Process package: A process package is a fundamental technical document provided by providers of patented process technologies. In accordance with the requirements of SHSG052-2003 \"Specifications for Process Design Packages (Comprehensive Technical Process Packages) for Petrochemical Plants\", it should include descriptions of the process technology characteristics, material lists, process calculations, PID diagrams, equipment selection, instrument control schemes, etc. It serves as the basic technical material necessary for individuals to master the process technologies in this field. l Engineering design techniques: First, one must be familiar with the design documents of one’s own equipment, as these serve as a basis for conducting problem analysis and technical improvements. Engineering design documents represent the engineering translation of process package technologies by engineering design firms. These documents include various components such as the process technology section in the “design description”, data sheets for process equipment, complete Process and Instrumentation Diagrams (PIDs), Utility Interface Diagrams (UIDs), process piping layout drawings, equipment layout plans, and design drawings for chemical equipment. Additionally, there are valuable materials like explanations regarding changes in process design and minutes from technical discussion meetings. Second, one must master the contents and procedures related to engineering design. This includes the ability to perform process design calculations (material and energy balances), equipment selection, and drafting (relevant requirements are also outlined in other sections of this paper). One should be capable of designing small-scale unit projects. Relevant engineering standards: These mainly include product quality standards specific to the relevant field, quality standards for raw materials (including an examination of how the unique characteristics of different manufacturing processes for these raw materials affect quality control in this system), energy consumption standards, safety, environmental protection, and occupational health standards, as well as standards for process design. 3. Scalability: In chemical machinery, one should understand the functions, working principles, internal structures, and maintenance methods of typical chemical machines and equipment (especially those used in plants, such as various pumps, heat exchangers, reactors, separators, etc.). One should also acquire basic knowledge of the main materials used in such plants, be able to conduct simple analysis and diagnosis of equipment problems, and think systematically when making changes during system modifications. It is recommended to read “Chemical Engineering Machinery”, “Design of Process Equipment”, etc. l Pipeline valves: Knowledge of pipeline design calculations, material selection, layout rules, and construction quality, as well as basic principles regarding valve selection and installation. Specific standards that can be studied include *GB20821 \"Code for Pressure Piping – Industrial Piping\", GB 50764-2012 \"Code for Design of Power Piping in Power Plants\", SH3012-2011 \"Code for Layout and Design of Metal Piping in Petrochemical Industries\"; foreign standards such as ASME B31.3 \"Process Piping\" and ASME B31.1 \"Power Piping\". l Electrical and instrumentation knowledge: Learn to master the basic knowledge of electrical instruments, as well as the working principles and structures of the electrical instruments commonly used in one’s work environment. In particular, the technologies related to instrument automation, ranging from the control valve assemblies on-site to the logical design of DCS and ESD systems in the control room, are closely linked to the unit operations in chemical processing. A thorough understanding of their structural characteristics, operational features, and logical relationships is of great significance for optimizing operations and ensuring safe operation. Remember! Promote Zhang Guangxin’s “Chemical Process Automation and Instrumentation”. l Analytical Chemistry: It is necessary to master the basic theories, fundamental knowledge, and experimental methods of analytical chemistry (especially those relevant to the analysis tasks performed by this device). It enables one to diagnose problems that arise during the analysis process. Additionally, it plays an important role in fostering a rigorous scientific attitude, a meticulous work style, and an engineering mindset based on facts. Advance in reading Wuhan University’s \"Analytical Chemistry\". l Safety management: Learn and master the basic knowledge in chemical engineering design; be able to comprehensively analyze and assess the hazards of equipment based on systematic scientific analysis. I recommend “Safety in Chemical Engineering Design” written by Professor Cui Keqing. Learn to use HAZOP (Hazard and Operability) qualitative analysis or quantitative risk assessment methods to analyze and evaluate the hazards in production facilities and processes, as well as their causes. It is recommended to read the “Guidelines for the Application of Hazard and Operability Study (HAZOP)”. Also, keep in mind: the above knowledge is also the foundation and guarantee for safety management. l Management skills: Understand the concepts, basic knowledge, and methods of business management. Recommended reading: Introductory management books such as “The Essentials of Management” and “Andy Grove: How to Manage”. Project management: It may not be possible to take on project management tasks, but learning to apply project management concepts and methods to manage one’s own work tasks will **improve our work efficiency. Recommendation: Harold Kerzner’s “Project Management”. In English: Being able to directly read foreign textbooks, standards, and other technical materials allows one to keep up with the latest foreign technologies as soon as they become available ； Second, read the original text directly to avoid errors in translation and interpretation. l Computers: First, one must master a technical computer language and develop small-scale computing management software on their own to **improve work efficiency**. Promote the use of VB programming, small database language programming, EXCEL function programming, etc. Second, it is necessary to master the ability to use AUTO-CAD software for computer-aided drawing. Third, one must learn to use professional process design software for process simulation calculations, including large-scale software such as PROII and Aspen Process Simulation, as well as smaller ones like RSTT-LC and CHEMCAD. l Quality management: Learn and master QC quality management procedures and methods, be familiar with the requirements of quality management system standards, and be able to guide teams in carrying out QC team activities to conduct systematic analysis and develop solutions to problems that arise during production. It is recommended to read \"ISO9001: Analysis and Resolution of Quality Issues\". l Cost management: Learn financial knowledge related to cost accounting, understand the composition of manufacturing costs as well as the rules for classifying and calculating them, identify promptly the key factors that affect costs, and offer professional suggestions for improvement. Promote the reading of the \"Guide to Corporate Cost Accounting Practices\". III. Cultivating good working methods and learning habits. 1. Go to the site in person and become familiar with the operations. First, one must cherish the opportunity to gain practical experience in the workgroup, master the operational skills of the DCS in the control room, and possess the capabilities expected of a lead operator. At the same time, communicating with front-line workers and building mutual trust helps with future cooperation and information exchange. Secondly, it is necessary to memorize the layout of pipes, valves, and equipment on site in order to improve one’s ability to diagnose faults and handle emergencies. Thirdly, only by being familiar with the site and having strong practical skills to handle problems can one establish credibility within the production team, which is beneficial for future management. 2. Knowledge management, improving quality. One should humbly learn from experienced skilled workers*. Among frontline workers, there are many individuals with specialized work skills and techniques, as well as extensive experience; their on-site expertise is highly valuable for conducting in-depth analysis and solving problems. Second, engage in technical exchanges through website forums and specialized blogs to learn from peers in the industry. Third, learn from internal experts and technical authorities*. Fourth, by following the websites of providers of process patents, one can stay informed about their advancements in new technologies and engage in timely communication. Fifth, take history as a guide: collect accident cases that have occurred within the own organization and in similar industries, carefully analyze their underlying causes, learn from them in daily work, and strive to avoid such incidents. Additionally, develop the habit of keeping daily work notes, and conduct thorough summaries after completing each key task in order to continuously accumulate work experience. Seventh is to properly collect and organize technical documents. Eighth, pay attention to learning knowledge related to relevant specialties. Actual production problems often involve various specialties and stages; mastering the various aspects of the \"expansion capability\" discussed in the previous section facilitates comprehensive analysis and judgment of such problems. 3. Cross-border management, willingness to take responsibility. In chemical production facilities, the process engineering discipline plays a leading role; it is responsible for taking the lead in organizing and coordinating other supporting disciplines, both in terms of production technology management and project construction management. This requires process engineers to not only possess interdisciplinary knowledge but also have an awareness of working in collaboration with specialists in areas such as equipment, machinery, instrumentation, and utility systems, making full use of their respective expertise while focusing on developing their own abilities in coordination and scheduling. 4. Strive for excellence and pursue perfection. When formulating a technical solution, comprehensive factors such as technological advancement, safety, and cost-effectiveness should be fully considered to identify the best option. In the case of production problems or accidents, it is not sufficient to merely explain the phenomena as they appear; rather, it is necessary to analyze the root cause of the problem. By using modern statistical methods (such as radar charts, moving range charts, pie charts, scatter plots, etc.), analytical techniques (such as the SAMM method, Gordon method, KJ method, PERT network analysis, matrix methods, etc.), theoretical calculations, and by referring to standard specifications, a scientific approach should be adopted to conduct thorough analysis and find effective solutions. 5. Be good at critical thinking and brave in innovation. Innovative and independent in thinking; not blindly following authority out of blind faith. Everyone has different areas of expertise and ways of thinking. Additionally, with the accelerating pace of technological updates and iterations, it’s difficult for any individual or organization to possess comprehensive knowledge. This, in turn, leaves room for individual innovation. Think critically about issues on a daily basis; for everything, ask yourself: Is there a better solution? By carefully thinking about the abnormal problems that arise, putting forward independent opinions and being able to express one’s views effectively, one can, first, strengthen oneself, and second, help oneself stand out more quickly and achieve success. 6. Unlimited communication, joint progress through cooperation. Communication includes interactions between superiors and subordinates, colleagues, various related specialties, as well as external partners (**regulatory agencies and collaborating organizations**), with the aim of obtaining information and resources to establish one’s own collaboration platform. Only by enduring hardships and dedicating themselves to continuous improvement can professionals in the field reach a new realm of freedom, become respected figures in the industry, and achieve success. Lunan, Zhang Fengkui, December 30, 2017