Advanced Chemical Engineering MSc

• Dr Mingming Zhu

This module is designed to give the students an advanced understanding of reaction kinetics, catalytic and non-catalytic gas-solid reactions, heat and mass transfer phenomena governing chemical reactions in energy engineering applications and experimental methods for kinetic measurements. The module also provide them with transferable skills in applications of reaction rate in reactor design and machine learning technique for catalyst/material design.

You will understand basics of reaction kinetics and thermodynamics and will learn how to design appropriate experimental methods to measure kinetics. 
 
You will learn how to model gas-solid reaction systems covering catalytic heterogenous reactions and non-catalytic reactions relevant to energy such as combustion, gasification, hydrogen production and CO2 capture. Within this breadth of systems, you will investigate the important role of mass and heat transfer in chemical reaction process in order to observe rate limiting steps to enhance/ chemical reactions.
 
You will learn new skills in using Chemkin to solve complex reaction systems and how to combine both reaction kinetics, transport and thermodynamic data into solving real problems that controlled by reaction kinetics such as hydrogen combustion and pollutants formation. 
 
You will also learn the latest research that is being undertaken to design new catalytic materials involving first-principals modelling aided by machine learning. You will learn of catalytic material synthesis methods and how these processes can be optimised for industrial applications. 

On successful completion of this module you should be able to:

• Critique different kinetic models and develop coherent and professional arguments that communicate how one could enhance overall reaction rates by overcoming rate limiting steps or properties of the solid material.
• Implement detailed kinetic reaction mechanisms in Chemkin and conduct sensitivity analysis.
• Design experimental methods to measure kinetics of gas-solid reactions and evaluate the effect of gas diffusion, reaction kinetics, and mass and heat transfer phenomena and the limits of knowledge/applicability in these areas.
• Apply latest machine learning technique to design catalysts and understand reaction mechanism.

• Dr Navid Khallaghi

The module provides you with the essential research techniques and hands-on skills to assess the technical feasibility and sustainability of chemical engineering processes through a combination of process simulations; techno-economic, life cycle, and social (sustainability) assessments; process safety; computational fluid dynamic modelling and machine learning. Considering, multidisciplinary nature of existing engineering challenges, this skill set is prerequisite for advancing research to enhance the performance of existing technologies, and offer innovative solutions for enabling emerging technologies.

The module comprises skills training on computer-aided engineering tools and research analysis approaches that enable you to develop relevant competencies via hands-on experience. You will also work on a relevant case study that will take you through the entire assessment process. The acquired research techniques will be then used to design, develop, and assess a wide range of complex and innovative chemical engineering cases for industrial applications in the follow-on applied modules within the course, including catalytic process, separation and purification, biofuel production and conversion, thermochemical energy conversion, bioprocessing, and thermal storage and management.

Process modelling and techno-economic assessment, and process safety

• Modelling and simulation: Concepts of process modelling. General concepts of simulation. Introduction to steady and dynamic process simulation. Introduction to commercial simulation software packages (i.e, Aspen HYSYS) for process flow-sheeting, design and analysis,
• Process optimisation techniques: Principles of optimisation,
• Case Studies (PC Lab and Demonstration Sessions): Process design, simulation and optimisation case studies based on industrial or research projects will be carried out using Aspen HYSYS and Aspen Plus,
• Economic assessment: Introduction to economic. Estimation of CAPEX and OPEX. Net present value (NPV).
• Process safety: Safety aspects of chemical processes.

Life cycle, social assessment

• Life cycle analysis: carbon footprinting and environmental impact assessment, waste management,
• Net-zero technologies for sustainable development: CO2 emissions and decarbonisation of transport, power and industrial processes,
• Social analysis: Social implication of technology deployment.

CFD modelling for engineering applications

• Introduction to CFD & thermo-fluids: Introduction to the physics of thermo-fluids, governing equations (continuity, momentum, energy and species conservation) and state of the art Computational Fluid Dynamics including modelling, grid generation, simulation, and high-performance computing. Case study of industrial problems related to energy, process systems, and the physical processes where CFD can be used,
• Computational Engineering Exercise: specification for a CFD simulation. Requirements for accurate analysis and validation for multi scale problems. Introduction to Turbulence & practical applications of Turbulence Models: Introduction to Turbulence and turbulent flows. Traditional turbulence modelling,
• Practical sessions: Fluid process problems are solved employing the widely used industrial flow solver software FLUENT. Lectures are followed by practical sessions on single/multiphase flows, heat transfer, to set up and simulate a problem incrementally. Practical sessions cover the entire CFD process including geometric modelling, grid generation, flow solver, analysis, validation and visualisation.

Machine learning for chemical engineering

• Create Machine Learning models in MATLAB: Predict, cluster, and simulate for chemical engineering problems. Understand and critique the differences between different Machine Learning algorithms.

On successful completion of this module you should be able to:

1. Critically assess the social and environmental sustainability, and safety aspects of processes or technologies, and evaluate the associated uncertainties through life cycle assessments,
2. Design and implement a strategy to carry out a process design and critically appraise the techniques and major commercial simulation tools for steady and dynamic process simulation,
3. Design and analyse the performance and techno-economics of process plants using simulation or optimisation tools,
4. Develop and implement CFD models for use in industrial design of complex systems,
5. Develop Machine Learning models for quantitative research analysis by means of prediction, clustering, and simulations of chemical engineering problems.

• Dr Ali Nabavi

The module provides the essential knowledge and hands-on skills for design and development of gas separation and purification technologies that are required for the decarbonisation of power and industry sectors, as the prerequisite to meet the net-zero emission target. 

The module enables you to master the underlying mechanisms of sorption and separation processes, along with the required experimental characterisation and data analysis techniques, and computational modelling. This knowledge will then be applied to design, develop, and evaluate carbon dioxide separation in power (i.e. gas and coal power plants) and industrial (i.e cement, iron and steel) sectors; biogas upgrading; hydrogen purification, and carbon dioxide and hydrogen storage, as case studies. 

 

• Principles of gas separation and purification:
  • Gas-liquid absorption/adsorption principles, 
  • Equilibrium and kinetic adsorption principles.
• Sorbent characterisation:
  • Design of experiments for characterisation of sorbents for separation and purification processes,
  • Characterisation of non-functional and functional sorbents using techniques such as scanning electron microscopy – energy-dispersive X-ray spectroscopy (SEM-EDX), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), Brunauer-Emmett-Teller (BET) surface area analysis and Barrett-Joyner-Halenda (BJH) pore size and volume analysis,
  • Data analysis techniques.
• Design and evaluation of gas separation, purification and storage technologies to achieve net-zero emission target:
  • Carbon dioxide separation in power and industrial sectors,
  • Biogas upgrading,
  • Hydrogen purification,
  • Direct air capture.
• Case Studies:
  • Case studies will be carried out using the acquired experimental data, and process simulations.

On successful completion of this module you should be able to:

• Apply the principles of gas adsorption and absorption in the design of separation and purification units,
• Characterise an analysis sorbents for the gas separation process,
• Critically evaluate the main challenges of carbon dioxide and hydrogen separation and storage in the energy sectors,
• Design and optimise separation and purification processes, contributing to achieving net-zero emission target. 

• Dr Vinod Kumar

The Biofuels and Biorefining module focuses on bioproduction of fuels and chemicals as a sustainable, environmentally friendly and low cost route This bioproduction can contribute to decreased greenhouse gas emissions, by replacing petrochemical route and also fulfil the global goals on the use of renewable energy.

The aim of the module is to provide you with advanced knowledge of the sources of biomass available for production of a range of high value chemicals and technologies used for conversion of the biomass. The module covers characteristics of biomass as potential feedstock, bioproduction of fuel and chemicals, types of biorefineries, conversion processes and existing technologies. In addition, an introduction to the Biorefining concept will be provided.

Raw materials for production of bio-based chemicals, characterization and assessment
Biofuel feedstocks and characteristics: starch- and sugar- based biomass, oleaginous-based biomass, lignocellulosic biomass, glycerol and algae.
Sugar, Fatty acid, and Syngas platforms technologies

First generation biorefinery
Bioethanol production
Biobutanol production

Biodiesel production
Biodiesel production technologies: biochemical, and catalytic and non-catalytic chemical processes. 
Biodiesel production: biochemical aspects.
Biodiesel production: chemistry and thermodynamic aspects.

Lignocellulosic biorefinery
Bioethanol production
Bioproduction of succinic acid
Bioproduction of 2,3-Butanediol
Bioproduction of Lactic acid

Algal Biorefineries
Technologies for microalgal biomass production
Algal biofuels conversion technologies

Food waste biorefineries
Manufacturing Platform Chemicals from food wastes

Glycerol-based Biorefineries
Bioproduction of 1,-3-Propanediol
Bioproduction of 3-Hydroxypropionic acid


AD-based biorefineries
Biofuel production by AD
Possible feedstocks and challenges

Biorefining
Classification of Biorefineries
Economic, social and environmental impacts of biorefining

Commercial biorefineries

On successful completion of this module you should be able to:

State and assess the range of biomass resources/ biowastes/ agro-industrial wastes available for biofuels and biochemicals production;

Critically evaluate a range of technologies and biorefineries available for biofuels and biochemicals production from biomass and analyse the potential for future reduction in costs through technological development;

Explain the main theoretical concepts and practical implementation associated with bioproducts engineering systems;

Identify the high-value products that can be obtained from biomass feedstock.

Construct simple biorefining schemes and critically evaluate the potential of biorefining processes.

• Dr Stuart Wagland

The module focuses on the opportunities for the conversion of biomass and waste to energy; industry-focused, providing you with a critical understanding of the key challenges in operating energy from waste facilities.  The module consists of visits to modern waste management facilities which include talks from the managers at each site to cover the day-to-day management of such technologies and aims to provide you with advanced knowledge of the sources of biomass and waste, and the range of technologies available for their conversion into energy, particularly focused on thermochemical conversion whereby opportunities for producing alternative fuels and chemicals from wastes will be explored. You will conduct laboratory exercises to characterise solid fuels (e.g. waste feedstock and solid residues), assessing the composition and characteristics of waste materials to critically evaluate the fuel properties of the samples.  Using analytical results to design thermochemical energy conversion systems using chemical modelling software (e.g. Aspen Plus).
 
Furthermore, the module provides you with a critical understanding of the key differences and challenges in pilot-scale working. The module will utilise several facilities at Cranfield as part of the taught sessions in addition to a visit to an external site, such as a waste management facility, to collect samples for analysis in the laboratory.  As a practical module, you will gain significant practical experience through lab practical sessions, computer simulation and industrial site visits.

• Policies driving and regulating thermal conversion (gasification and pyrolysis) and incineration technologies;
• Understanding how and why waste composition changes and the effects of these changes on the energy potential.  Explored further as part of a practical session covering waste and waste-derived fuel characterisation;
• Material characterisation (elemental analysis, calorific value, thermal decomposition (TGA) and analytical skills for fuel products characterisation).
• Principles and reaction mechanisms of Gasification, pyrolysis and Combustion.
• Design principles of thermochemical processes and appropriate full energy system integration
• Facility management challenges including process and emissions monitoring, health and safety compliance, and maintenance routines;
• Management of post-energy recovery residues (bottom ash, fly ash, digestate etc)
• Complex chemical and thermal process modelling using ASPEN Plus

On successful completion of this module you should be able to:

1. Characterise and select the most appropriate biomass and waste materials for energy conversion applications,
2. Design and assess appropriate energy conversion systems for bioenergy production from biomass and waste,
3. Develop and apply analytical skills to carry out process simulation for design of energy conversion systems,
4. Critically evaluate the main operational challenges in operating thermochemical processes, reviewing current practice to identify potential areas for research and development,
5. Critically evaluate the application of software packages relevant to chemical engineering for upscale design from pilot-scale results to demonstration and commercial scale plants.

• Dr Adriana Encinas-Oropesa

The purpose of this module is to provide you with experience of planning a project that will involve scoping and designing a product.  The module provides sessions on project and planning, including sustainable design principles, project risk management and resource allocation. A key part of this module is the consideration of systems thinking approach for creating innovative solutions, ethics, professional conduct, and the role of an engineer within the wider industry context as well as considerations for equality, diversity and inclusion.

Project Management,
Ethics, EDI and the role of the engineering (ethics case study),
Product development,
Circular Economy,
Systems thinking,
Innovation.

On successful completion of this module you should be able to:

• Apply design thinking methods and techniques to generate a product design concept that can be scaled up to a commercially viable solution.
• Design and plan the product project including processes, resources required (human and material), product end-of-life and risk management.
• Integrate systems thinking and circular economy approaches to develop sustainable and innovative products.
• Evaluate ethical dilemmas, equality, diversity and inclusion (EDI), and the role of the engineer within the context of their chosen industry.

• Dr Ali Nabavi

Design of optimum thermal and energy storage systems is one of the key prerequisites to enhance the performance and efficiency of conventional and future energy systems and chemical processes.

This module aims to enable you to combine and apply the principles of heat transfer, thermodynamics and fluid mechanics in the design and optimisation of commercial thermal systems. In addition, the module introduces you to a wide range of challenges and opportunities in waste heat recovery and energy storage, and provides practical approaches and solutions to enhance the system efficiency.

Heat exchanger Design and Operation
Heat exchangers: Classification. Theoretical principles and design of recuperative systems (effectiveness, NTU and capacity ratio approach for parallel-, counter- and cross-flow configurations). Regenerative heat exchangers (intermittent and continuous systems). Heat exchanger optimisation (optimal pressure drop and surface area to maximise economic returns. Health and safety design considerations of heat exchangers.

Process integration: Problem table method. Heat-exchanger network. Utility systems. Fundamentals of pinch analysis and Energy Analysis.  

Refrigeration systems

Application of refrigeration

Vapour-compression refrigeration systems: Multi-stage compressor systems. Multi-evaporator systems.

Absorption refrigeration: Absorption refrigeration for waste heat recovery. The absorption process. Properties of fluid-pair solutions. Design of absorption cycles. Double-effect systems.  Advances in absorption-refrigeration technology.

Heat Recovery and Thermal Storage

Heat recovery: Heat recovery for industrial applications.

Thermal storage: Principles and application to hot and cold systems. Storage duration and scale. Sensible and latent heat systems.  Phase-change storage materials.  

Thermal system modelling

CFD modelling of thermal systems: Development and optimisation of CFD models for simulating thermal systems. Case studies for development of analytical solutions for design of thermal systems. 

On successful completion of this module you should be able to:

• Analyse and design heat exchangers, competently applying the principles of heat transfer, thermodynamics and fluid mechanics,
• Construct optimised heat exchanger networks by applying principles of process integration,
• Recognise and debate  the issues related to the efficient use of thermal energy and appraise  techniques and technologies employed,
• Design and analyse the performance of refrigeration and air conditioning systems.

This module introduces a systematic approach to the design of measurement and control systems for industrial process applications. The fundamental concepts, key requirements, typical principles and key applications of the industrial process measurement and control technology and systems will be highlighted.

Principles of Measurement System

• Process monitoring requirements: operating conditions, range, static performance, dynamic performance,
• Sensor technologies: resistive, capacitive, electromagnetic, ultrasonic, radiation, resonance,
• Signal conditioning and conversion: amplifiers, filters, bridges, load effects, sampling theory, quantisation theory, A/D, D/A,
• Data transmission and telemetry: analogue signal transmission, digital transmission, communication media, coding, modulation, multiplexing, communication strategies, communication topologies, communication standards, HART, Foundation Fieldbus, Profibus,
• Smart and intelligent instrumentation. Soft sensors. Measurement error and uncertainty: systematic and random errors, estimating the uncertainty, effect of each uncertainty, combining uncertainties, use of Monte Carlo methods,
• Calibration: importance of standards, traceability,
• Safety aspects: intrinsic safety, zone definitions, isolation barriers,
• Selection and maintenance of instrumentation.

Principles of Process Measurement and Control

• Flow measurement: flow meter performance, flow profile, flow meter calibration; differential pressure flow meters, positive displacement flow meters, turbine, ultrasonic, electromagnetic, vortex, Coriolis flow meters,
• Pressure measurement: pressure standards, Bourdon tubes, diaphragm gauges, bellows, strain gauges, capacitance, resonant gauges,
• Temperature measurement: liquid-in-glass, liquid-in-metal, gas filled, thermocouple, resistance temperature detector, thermistor,
• Level measurement: conductivity methods, capacitance methods, float switches, ultrasonic, microwave, and radiation method,
• Multiphase measurement and monitoring: general features of vertical and horizontal multiphase flow, definition of parameters in multiphase flow, multiphase flow measurement strategies, Content and composition measurement, velocity measurement, commercial multiphase flow meters, developments in multiphase flow metering,
• Typical process control philosophy: Closed loop controls and AI controls .

Practical of Process Control

• Case study 1: Process Plant Integrity Monitoring,
• Case study 2: Separation Process Control System in a Pilot Plant.

On successful completion of this module you should be able to:

• Critically assess the factors affecting the operation of a process sensor and the types and technologies of modern process sensors,
• Examine the factors to be considered when designing a process measurement and control system,
• Propose the most appropriate measurement system for a given process control application.