Day In The Life Of A Chemical Engineer (Process Engineer) | What Do Chemical Engineers Do?

Eggs the Engineer
25 Feb 202114:04
EducationalLearning
32 Likes 10 Comments

TLDRThe video script offers an insightful look into the daily life of a chemical engineer in a process engineering role. It highlights the dynamic nature of their work, which involves understanding process systems, troubleshooting, managing tests, and dealing with process changes. Chemical engineers oversee continuous operations, quality control, and long-term projects, often collaborating with various teams to ensure efficiency and safety. The script emphasizes the problem-solving skills required and the variety of tasks that a chemical engineer might undertake, from dealing with immediate issues to planning for significant process improvements over months or even years.

Takeaways
  • 👔 A chemical engineer's attire should be practical for the potentially messy environment of a chemical plant.
  • 🕒 Chemical plants operate 24/7, necessitating frequent meetings for shift changes and continuous process updates.
  • 🔍 Process engineers understand the fundamentals of a process system and assess the impact of potential changes.
  • 📊 They focus on the entire process system, from raw materials to the final product, looking for improvements and troubleshooting.
  • 🚫 Process engineers are typically not involved in day-to-day operations but step in for significant process changes or issues.
  • 🔧 They handle quality issues, such as investigating why industrial-scale cookies are turning out with unexpected colors.
  • 🧪 Process engineers manage tests, ensuring that potential risks and changes are accounted for and that quality remains consistent.
  • 🔄 Startups and shutdowns of processes are times when process engineers are most needed due to the high likelihood of issues.
  • 🔍 Root cause analysis is a key skill for process engineers, often required to investigate process failures or quality issues.
  • 📅 Long-term projects for process engineers can span months or years and involve extensive planning, risk analysis, and coordination.
  • 🌿 Chemical engineers may work on large-scale projects involving raw material changes, such as incorporating recycled materials into production.
Q & A

  • What is the primary role of a chemical engineer in a process engineering setting?

    -A chemical engineer in a process engineering setting primarily focuses on understanding the fundamentals of the process system and determining the impact of changes on it. They look at the entire process, from raw materials to the final product, and work on troubleshooting, optimization, and implementation of new procedures or equipment.

  • How often do chemical plants typically run?

    -Chemical plants usually operate on a 24/7 basis, with continuous processes that rarely stop except for maintenance a few times a year.

  • What is the purpose of the morning meeting in a chemical plant?

    -The morning meeting allows for a turnover from the overnight shift to the day shift and provides an opportunity for managers and engineers to get updated on the plant's operations and any issues or changes that may have occurred overnight.

  • What kind of projects might a process engineer work on in the short term?

    -In the short term, a process engineer might work on addressing immediate problems identified in morning meetings, conducting tests with new installations or processes, or managing startups and shutdowns of equipment.

  • How does a process engineer approach a quality issue with a product?

    -A process engineer will investigate the root cause of the quality issue by examining the raw materials, processing conditions, and any changes in the supply chain that could affect the product. They may also conduct tests or experiments to identify and resolve the problem.

  • What are some long-term projects a process engineer might be involved in?

    -Long-term projects for a process engineer could include the installation of new equipment, revamping quality control systems, implementing new production lines, or integrating new materials or additives into the process.

  • What is involved in the startup and shutdown process of a chemical plant?

    -Startups and shutdowns involve careful planning and monitoring to ensure that the process changes from stopped to running or vice versa without causing issues. Process engineers are crucial during these times to prevent problems such as equipment damage or safety hazards due to sudden changes in temperature or pressure.

  • How does a process engineer handle a persistent quality issue?

    -For persistent quality issues, a process engineer might modify the operating procedure, conduct root cause analysis, and implement new tests or procedures to address the problem without shutting down the process.

  • What is the role of a process engineer in root cause analysis?

    -A process engineer specializes in root cause analysis to identify the underlying reasons for process failures or issues. They work with teams to investigate, find solutions, and implement measures to prevent recurrence of the problem.

  • How do process engineers manage the risks associated with new equipment or processes?

    -Process engineers conduct risk analysis, develop safety procedures, and ensure that operators are trained for new equipment or processes. They also plan for potential changes in maintenance and quality control to accommodate the new risks.

  • Why is it difficult to provide a comprehensive picture of a process engineer's day-to-day activities?

    -The activities of a process engineer are highly variable and dependent on the specific issues and projects at hand. Additionally, many aspects of chemical processes are confidential, making it challenging to showcase the full range of tasks without revealing sensitive information.

Outlines
00:00
👔 Daily Routine and Morning Meeting

The video begins by introducing the daily routine of a chemical engineer in a process engineering role. The engineer starts the day with preparations suitable for working in a chemical plant, emphasizing the need for practical attire due to the potential messiness of the environment. The first key activity is attending a morning meeting at 7 am, which is crucial for the transition from the overnight shift to the day shift. This meeting is an opportunity for team members, including managers and engineers, to discuss ongoing processes and issues. The chemical engineer's role is to understand the process system fundamentals and assess the impact of potential changes. The summary highlights the importance of the morning meeting in maintaining a 24/7 operational chemical plant and the collaborative nature of problem-solving among team members.

05:01
🔍 Role and Responsibilities

This paragraph delves into the specific responsibilities of a process engineer. Their job extends beyond routine maintenance and operation, focusing on understanding the entire process system from raw materials to the final product. The process engineer is likened to having x-ray vision, needing to comprehend what's happening within the machinery. They attend meetings to discuss ongoing projects, address process issues, or assist with unexpected changes. The daily tasks can range from dealing with immediate problems identified in the morning meeting to long-term projects planned months in advance. The summary underscores the process engineer's role in troubleshooting, quality control, and planning for both short-term and long-term operational changes.

10:02
📈 Problem-Solving and Quality Control

The paragraph discusses the process engineer's involvement in problem-solving and quality control. They are often called upon when operators and maintenance personnel cannot resolve issues. Scenarios include dealing with quality issues, such as color discrepancies in products, requiring the engineer to investigate potential chemical changes in raw materials or dosing errors. The process engineer may also manage tests to introduce new additives or evaluate the impact of changes in suppliers. The summary highlights the engineer's analytical skills in conducting root cause analysis to prevent recurring issues and their proactive approach in planning for potential risks associated with process changes.

🚀 Long-Term Projects and Continuous Improvement

This section covers the long-term projects and continuous improvement initiatives that a process engineer may work on. These projects can span weeks, months, or even years, such as revamping quality control systems, introducing new production lines, or incorporating new materials into the process. The engineer is involved in various stages of these projects, from ordering parts and coordinating with suppliers to planning for startup procedures and risk analysis. The summary emphasizes the process engineer's role in driving innovation, managing risks, and ensuring that new equipment and processes are integrated smoothly and safely into the existing operations.

Mindmap
Keywords
💡Chemical Engineer
A professional who applies the principles of chemistry, physics, and mathematics to solve problems involving the production or use of chemicals, materials, and energy. In the video, the role of a chemical engineer in a process engineering setting is explored, highlighting their involvement in understanding and optimizing industrial processes from raw materials to final products.
💡Process Engineering
A branch of engineering that deals with the design, development, and operation of processes that convert raw materials into valuable products. It involves the continuous and efficient functioning of chemical plants and other industrial facilities. The video emphasizes the importance of process engineers in maintaining and improving these processes to ensure smooth operations and address any arising issues.
💡Continuous Process
A type of industrial process that operates continuously without interruption, typically 24/7, to produce a product. This is in contrast to a batch process, which involves distinct cycles of production. The video explains that chemical plants often run on a continuous basis, necessitating a workforce that covers all hours of the day and involves process engineers in maintaining this continuous operation.
💡Morning Meeting
A regular meeting that takes place at the start of the workday, often used to discuss updates, plan tasks, and address any issues from the previous shift. In the context of the video, the morning meeting is crucial for process engineers to receive updates on the plant's operations and to coordinate with other team members for the day's activities.
💡Troubleshooting
The process of identifying, preventing, and solving problems in a systematic manner. In the video, troubleshooting is a key responsibility of the process engineer, who must diagnose and resolve issues within the chemical process to prevent disruptions in production.
💡Quality Control
A set of procedures and tests that ensure a product or service meets certain standards of quality. In the video, quality control is a critical aspect of the chemical engineer's role, as they must monitor and adjust the process to maintain the desired quality of the final product.
💡Startups and Shutdowns
The initial start-up and eventual shutdown of a process or machine, which often involves a series of specific steps and procedures to ensure safety and efficiency. In the video, startups and shutdowns are times when process engineers are particularly needed to manage the complex changes and potential issues that can arise during these transitions.
💡Root Cause Analysis
A method of problem-solving that aims to identify the underlying causes of a problem, rather than just addressing its symptoms. In the video, process engineers use root cause analysis to investigate process failures or issues and to implement corrective actions to prevent recurrence.
💡Long-Term Projects
Projects that are planned and executed over an extended period, often involving multiple stages, resources, and stakeholders. In the video, long-term projects such as the installation of new equipment or the development of new processes are part of the chemical engineer's responsibilities, requiring extensive planning and coordination.
💡Risk Analysis
The process of evaluating potential risks and determining their impact on a project or operation. In the context of the video, process engineers perform risk analysis to identify and mitigate potential hazards associated with new equipment, process changes, or other modifications to the production system.
Highlights

Chemical engineers work in process engineering roles to understand and optimize chemical processes.

Chemical plants typically operate 24/7, necessitating continuous processes and overnight shifts.

Daily morning meetings are crucial for sharing updates and coordinating between shifts.

Process engineers focus on the entire process system, from raw materials to final products.

Engineers often deal with immediate issues such as process disruptions or quality upsets.

Quality issues, like color discrepancies in products, require investigation by chemical engineers.

Process engineers manage tests and trials to optimize processes and incorporate new elements.

Startups and shutdowns of chemical processes can be complex and require expert oversight.

Chemical engineers may work on long-term projects like equipment installations and process improvements.

Root cause analysis is a specialized skill of process engineers to troubleshoot and prevent future issues.

Engineers must consider safety and environmental impacts when introducing new processes or equipment.

The role of a process engineer involves a mix of daily problem-solving and long-term planning.

Chemical engineers adapt to the ever-changing needs of the process, which directs their daily tasks.

Large-scale projects, such as incorporating recycled materials, require extensive planning and collaboration.

The video aims to provide an informative insight into the diverse and complex role of chemical engineers.

Understanding the full scope of a process engineer's work may take months or years of experience.

Chemical processes are often secretive due to proprietary and security concerns.

Transcripts

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Chemical EngineeringProcess OptimizationIndustrial ProcessesDaily ChallengesMaintenanceQuality ControlInnovationProblem SolvingShift MeetingsProject Planning