Here's how you can master process optimization as a chemical engineer.

Mastering process optimization starts with a solid understanding of the basics. This includes a firm grasp of chemical engineering principles, thermodynamics, fluid dynamics, and reaction engineering. Familiarize yourself with process flow diagrams (PFDs) and piping and instrumentation diagrams (P&IDs). Early in my career, I found that dedicating time to thoroughly understand the processes I was working on allowed me to identify inefficiencies and areas for improvement more effectively. This foundational knowledge is critical as it enables you to see the bigger picture and understand how changes in one part of the process can impact the whole system.

As a chemical engineer, understanding the basics such as material and energy balance, process calculations, thermodynamics, fluid mechanics etc. gives you a broad knowledge of how to visualize and conceptualize the processes. In addition, a good grasp of PFD and P&IDs helps to actualize and identify bottlenecks in the process as well as proffer solutions the problems encountered in the processes.

Deep understanding of Energy and Mass Balance is the most important knowledge for a chemical process engineer. I would add Bernoulli Equation, and friction loss equations, that are vital to understand the pressure dynamics through the system, and for valves and pumps sizing, and troubleshooting.

Based on my experience mass and energy bilance togheter with termodinamics and kinetics are fundamental to optimize the process including reaction and separation,with the development of products including by products and waste.The knownledge of side reation allows to extimate the selectivity of the process and permit to optimize the type of reactors tipically cstr or pfr.

At HRC fuels, we know that most if not all the existing Refinery LP models are significantly under optimizing refinery gasoline blending Our patented discoveries on how to produce paraffinic gasoline with the octane synergy of ethanol blending at 145 octane and aromatic amines blending at 425 octane means we have solved the octane problem without expensive naphtha reforming. We reduce the cost of making ethanol blended gasoline by $6/bbl however…without an LP pathway in the model this option is unavailable to the solution sets. Paraffinic gasoline reduces both Scope 2 and Scope 3 emissions but most LP’s give no economic consideration to these benefits Additionally, gasoline carcinogenicity is reduced 90% via BTX reduction.

Mastering support tools like process simulators allows us to predict complex process, and make many adjustments in short time. I would suggest also open source tools like DWSIM Process Simulator.

Based on my experience i succeeded in optimizing the performance of isobutane distillation unit in HF alkylation plant with chemcad.with simulation i discovered that the disc in flow meter instrumentation of isobutane was inverted and the reading on dcs was incorrect.After simulation i understud what was the value of flow rate.After maintenance to instrumentation the run of column was normal.

Data analysis is at the heart of process optimization. Tools like PI AF and SEEQ are invaluable for this purpose. PI AF helps structure and contextualize data, making it easier to spot anomalies and performance issues. SEEQ’s advanced analytics capabilities allow for deeper insights through features like pattern recognition and predictive analytics.

You can only improve what you can see, understand and measure. Data analysis is critical for process optimization. There are a lots of old tools and techniques for process optimization, but I think AI will make significant breakthrough in process optimization in the near future so keep learning about about the power of AI and how to implement it in your industry and processes.

Staying up-to-date with the latest advancements in process optimization tools and methodologies is essential. Regularly attend workshops, webinars, and industry conferences. Engaging with professional networks and forums can also provide valuable insights. Personally, I make it a point to dedicate time each month to learning about new features in tools like PI Vision or SEEQ. This continuous learning approach has not only kept my skills sharp but also introduced me to innovative techniques and strategies that have enhanced my ability to optimize processes effectively.

I had one uncle that used to say: "The most important thing you must learn in an engineering course, is to learn how to learn, everything else may become outdated". There are always new technologies, and also old technologies that we didn't know yet. What was done in the past, always can be done better in the future, so we must be always learning more.

I found very useful joining Icheme professional organization of chemical engineers .They gives you the opportunity to be in contact with other collegues all over the worldWith them you can share knowledge,information and also you can be updated with the facts happening in chemical industry

Never be afraid to change something, but discuss previously with as much people as possible, for different specialities, in order to optimise and find the possible weakness of the new change. Try to simulate and predict everything that could wrong, evaluate and mitigate all the risks before going ahead. And remember that we must always present the economical benefits, not only technical improvement.

Evaluating the outcomes of implemented changes is vital for mastering process optimization. Use PI AF and SEEQ to track performance metrics and analyze the impact of optimizations over time. Continuous monitoring with tools like Grafana ensures that any deviations from expected performance are quickly identified and addressed. In my experience, setting up a comprehensive evaluation framework helped us maintain process efficiency and achieve our energy-saving goals. Regular evaluation not only confirms the success of implemented changes but also provides insights for future optimization opportunities.

It is nice to have a system with higher efficiency and performance. At the end of the day, the company has to be profitable to stay in business. However, profits can come from momentary values such as money or it could be social or regulatory. Make sure to design a system that meets the objective.

Learn the basics needed like reading P&ID diagrams and mastering the necessary software But also be flexible, ready to adapt and hungry to learn

In addition to mastering the tools and techniques, consider the importance of collaboration and communication within your team. Share insights and learnings with colleagues, and be open to their suggestions and feedback. Furthermore, always keep safety and regulatory compliance at the forefront of any optimization effort. Stay informed about industry standards and best practices. Finally, cultivate a mindset of continuous improvement—optimization is not a one-time effort but an ongoing process that evolves with technology and industry trends. Embracing this mindset will ensure long-term success and sustainability in your process optimization endeavors.

An often overlooked aspect in process optimization is the timeframe and controllability of the processes being optimized. This becomes crucial when optimizing within an operational unit in the chemical industry. Failure to consider controllability and real-world applications during mathematical optimization can render the results impractical for implementation in operational settings.

In contact with chemical engineering association like icheme or aidic you can have an open window to what's happening in chemical world