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How Chemical Engineering Will Drive The 21st Century?
How Chemical Engineering Will Drive The 21st Century?
Partha S. Ghosh
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
How do you sense the “State of Health” of
our Planet?
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The Recent Past, 20 Years back 5,000 Million
60,000 65 Billion
Million Metric Tons
50,000
Tons by 2050
40,000
30,000
20,000
10,000
0
1980 1990 2003 2010 2020 2025 2050
Boston Analytics Research
1. Energy Information Administration (http://www.eia.doe.gov) Year
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
How Hot will Boston be?
60
50
39.3
40
31.5
30 25.5
20 15.7 17.7
9.5
10
0
1961 to 1990 2010 to 2039 2040 to 2069 2070 to 2099
Projections
Lower emissions Higher emissions
Boston Analytics Research
1. “Union of Concerned Scientists”, Joan Mclaughin/Globe Staff
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Global Warming is Lethal?
Changes in
activities, • Rise in Sea level
3%
land use,
9% • Reductions in the ozone
Agricultural layer
practices,
14% • Increased intensity and
Energy use
frequency of extreme
and weather events
Chlorofluor production,
ocarbons, 57% • Impacts on agriculture
17%
• Spread of disease
Greenhouse Gases (GHG e.g. CO2)
Boston Analytics Research
1. “Causes of Global Warming” (http://library.thinkquest.org/26026/Statistics/causes_of_global_warming.html)
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Sea level is expected to Rise: How much?
350.0 345.0
300.0
250.0 212.7
200.0
150.0 116.7
100.0
54.9 56.2
38.0
50.0 17.1 23.8
4.8 13.0
0.0
2000 2025 2050 2075 2100
Conservative Scenario High Scenario
Europe 1,538
Asia 211
-8,053 South
America
-8,415 Africa
-16,184 World
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
In fact the US has lost considerable forest area
1620 1920
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Dynamics of Deforestation and Ecology: Require
Repurposing our Chemical Engineering Knowledge
• Less CO2 taken in
• Burning Trees adds even more
CO2
• Less photosynthesis takes
HYDROSPHERE ATMOSPHERE
place
• Increased risk of fire
GEOSPHERE BIOSPHERE
• Soil Erosion
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Powerful Forces at Work?
Changing Ecology
65 Billion Increasing
Tons of CO2 Population
Rising
Temperature Equity
Increasing
Sea Level Deforestation
Finite Resources
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Powerful Forces at Work: Clash of Perspectives?
Deforestation
Increasing
Sea Level
Finite Resources
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Most of the world is still in the early stage of Economic
development
120 Canada
Energy Consumption
(‘000 KWHr / Capita)
100 US
80% of Global
80 Population
60 Russia France
Germany Japan
Kazakhstan Czech
UK
40 Ukraine Republic Italy
Malaysia
Thailand Romania
20 Brazil
China Turkey
Indonesia Egypt Philippines
India 0
0 5000 10000 15000 20000 25000 30000 35000 40000 45000
GDP / Capita (US$)
Boston Analytics Research
1. Energy Information Administration - EIA (http://www.eia.doe.gov/)
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Future Natural Gas requirement of Asia
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
If China & India consumes energy @ 25% of US/capita
total energy consumption will increase by 41.6 T KwHr
41.6
Energy Consumption
150
130.8
(Trillion KWHr)
100
50
0
Actual Estimated*
* Per capita energy consumption of the selected countries is 25% of US per capita energy consumption
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Old Path or New Path: Time to Choose?
Plastic Consumption per capita in Selected Countries vs.
GDP per capita (2003)1,2,3
Plastic Consumption per capita (in kg)
140
2
Developing and R = 0.8631
120 Moderately Developed Germany US
Countries
Singapore Japan
100
80 Canada
60
Malaysia
40
Hungary Highly
20 Thailand Developed
China Poland Countries
Indonesia
0 India
0 5000 10000 15000 20000 25000 30000 35000 40000
1973 – Yom
Kipper War
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Cleary we are at the End of a Long Era?
Economic Development Curves
High
Information
Revolution
Productivity of Society
Industrial Revolution 2
(Internal Combustion
Engine)
Industrial Revolution 1
(Steam Engine)
2005 ~2010
Low
Time
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The Essential Points:
1. Indeed Challenging & Interesting times
ahead
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Mega Challenge = Managing a Mega Transition
to avoid Mega disruption
1350 1900 2005 ~2010 2050
PROBLEMS ≈ OPPORTUNITIES
Holistic Approach
Renewable and
Energy Clean Energy
Source
Ecology Equity
Energy ,Food
and Health for All
Sustainable Economic
Developed
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Scope of the Field?
Chemical Industry’s Future (?): Two Strategic Vectors
Balance?
Conservation
driven
Balance of Ecology
Future Chemical
Engineer
Consumption
driven Perspective?
Point Balance of Economic Holistic/Integrative
Solution Advance Solution
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Expanded Field?
Chemical Industry’s Future (?): Two Strategic Vectors
Balance?
Conservation
System Transportation
Management
Future Chemical
New Engineer
Chemistry Recycling
of Waste
for the Car
Agro based
Recycling Chemical
Lighter
Products Industry
Today
Improved
Consumption functionalities Process
Intensification
Perspective?
Point Balance of Economic Advance Holistic
Solution Solution
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Strategic Direction of Chemical Industry
Positive
Create New Investment in Next
generation
Game Knowledge Intensive
Energy/Materials
Balance of
Solutions: “Small is
Ecology
beautiful”
Energy Efficient
consumption
Negative
Negative Positive
Balance of Economic Progress
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Mega Challenge = Managing a Mega Transition
to avoid Mega disruption
1350 1900 2005 ~2010 2050
Thermodynamics
Chemical Industry’s
Knowledge Asset
(How far?)
Kinetics
Extraordinary
(How fast?)
Knowledge base
Size Reduction
(Rooted in the early
Stages of Industrial (Surface Properties ?)
Revolution)
Transport Phenomena
(Flow Mechanisms?)
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
And Look for Mega possibilities @ the Intersection of
Conventional Engineering & New Technologies
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The Promise of Chemical Industry has to be
applied in Multiple Scales
Three Scales of Knowledge Application
Holistic /Tera Scale
Perspective
Large Scale Systems Dynamics Tera Scale
Issues
1 •Global Ecological Balance ?
• Energy Balance ?
• Social Structures ?
Scales of Engagement
Current
Scale
2 1. Efficiency
2. Conservation
3. Recycling
Raw materials
Micro Nano
Cellular /Nano Scale
3 Level
functionalities
Microscopic
Perspective
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The Promise of Chemical Industry has to be
applied in Multiple Scales
Three Scales of Knowledge Application
Holistic /Tera Scale
Perspective
Large Scale Systems Dynamics Tera Scale
Issues
of
1 •Global Ecological Balance ?
s s
• Energy Balance ?
• Social Structures ?
c e
o es
Scales of Engagement
r
P in Current
n l Scale
2 ti o cip 1. Efficiency
za is 2. Conservation
l i d 3. Recycling
Raw materials
i a le
o c ip
S/Nanoult
Micro Nano
Cellular Scale
3 Level
M
functionalities
Microscopic
Perspective
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
New technologies could indeed trigger a New Era
Process Industry Reconfiguration
Nano Information
Technologies Technology
10011000101110
Upstream Downstream
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Towards an Agro cell based Economic
Revolution?
Development of a More Sustainable Economic Model
High
Towards improved
Information new
Productivity of Society
Revolution
socioeconomic
structures with a
Industrial Revolution 2 “new agro” based
(Internal Combustion revolution
Engine) Symbiosis
Agro-cell of Multiple Disciplines
Based
z Genomics / Biosciences
Industrial Revolution 1 z Unit operations
(Steam Engine) z Bio Catalyst
z Convergence technologies
†
(4 C’s)
Low
Time
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
For Example: An Agro Complex?
Resource Industry Critical Issues Resource Industry Critical Issues
Cereal Crops z Increase in yield (kg / hectare) Chemical Industry
z Quality and consistency?
Fruits Vegetables
z Distribution system?
Down stream value addition Dyes and
Tea
Food and z
Flowers
and branding? Pigments
Beverage
Algae z Knowledge sharing and
Vegetables
awareness building?
Natural Rubber
Aqua Products Polymers z Development of low cost
process equipment and
Starch and Epoxy controls?
Cotton Fiber, z Cost Effectiveness?
Glues z Storage and distribution system?
z Quality consistency? Lignins
Silk
Fabric z Economics of scale and cost
z Familiarity with fashion trends?
and Alcohol competitiveness?
z New application on Solvent and
Jute Fashion development?
Starches Chemicals
Bio-mass z Knowledge sharing
z Low cost equipment Jute Stick Board z Knowledge sharing application
Wind Farming development? development?
Furniture /
Energy z Promotional activities? Chip Board z Machinery development for
Seed Oils Constrn. rural use?
Renewable Wood z Development of hot stamping
Starches technology?
Sugar Cane
Paper, z Knowledge Sharing and
Specialty Chemical Industry Straw application?
Paper
z Low cost machinery
Herbs Pharmaceu Jute Board and development?
z Awareness building?
ticals and Packaging z Incentives for corporate sector?
Medical Plants z Involvement of university Waste Woof Pulp
Ayurvedics professionals?
Algae / Azola z Incentives for corporate Rapeseed z Promotion of new application
sector? based on agro?
Perfume Lequerella Oil and
Vegetable Oil z Venture funds “bottom up” z Availability of venture funds?
Personal development? Castor Seed Lubricants z Creation of down stream pillars?
Flowers Care
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Biotechnology could enable production of better breeds
of trees enabling fast and healthy reforestation
Tree Breeding and Seed Production Processes1
3. Breeding: After testing, better wild parent
trees are selected for the breeding program.
The aim is to increase the extent to which the
4. Production:
desired characteristics are shown in every
Cuttings from the wild
subsequent generation
parent trees are
grafted in the orchard
in a random pattern
and allowed to cross-
pollinate
1. Selection: The
selection process
involves the finding 2. Testing: In the
wild trees which testing phase,
possess the desired researchers try to find
traits (e.g. pest those parent trees
resistance, superior that carry the best
growth or form etc) genes for the desired
characteristics
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Biocatalysts: Using enzymes as catalysts for synthesis
in mild conditions?
Biocatalysis in the Manufacture of Polymers1
Enzymes act as
biocatalysts enabling
precision polymer
synthesis
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Development and fine tuning of Biofuels
Technologies could open up new vistas
Feedstocks
Feedstocks Conversion
Conversion Fuel
Fuel End-
End-Use
End-Use
Thermochemical Conv.
Consumer
Consumer Hydrogen
Hydrogen
Residues
Residues
Gasification
Gasification Fuel
Fuel Cell
Cell
Syngas
Vehicles
Vehicles
Agricultural
Agricultural Pyrolysis
Pyrolysis Methanol
Methanol
Residues
Residues Liquif
Liquif &
& HTU
HTU
Bio-Oil
Bio-Oil
Fiber
Fiber Biochemical Conv. (Fischer-
(Fischer- Gasoline
Gasoline
Residues
Residues Tropsch)
Tropsch) Vehicles
Vehicles
Anaerobic
Anaerobic
Digestion
Digestion
Cellulosic
Cellulosic Biogas
Biogas
Peren.
Peren. Crops
Crops Fermentation
Fermentation
&
& Distillation
Distillation
Diesel
Diesel
Energy
Energy Microbial Vehicles
Microbial Ethanol
Ethanol Vehicles
Crops
Crops Digestion
Digestion
Biodiesel
Biodiesel (Veg.
(Veg.
Oil
Oil Extraction
Extraction Oil
Oil Methyl
Methyl
Crops
Crops Esters)
Esters)
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Cellulosic ethanol is on the horizon
Process Description Pilot plants
Fermentation Conventional ethanol from 2% of U.S. gasoline
sugar
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Biomass Energy development will require a full range of
conventional Chemical Technologies
Different Technologies to Harness Biomass Energy1,2
Biomass
Combustion of biomass to produce electricity
Combustion
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Power & Energy: Large Scale Engineering
systems thinking is essential
BioEnergy
Engines
Wind Farm PV Array
Stirling
Rooftop PVs
Transmission and
Distribution
Fuel Cells
Residential Commercial
FuelMicroturbines
Cells
Reciprocating engines
Industrial
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Solar Energy has the potential to address our growing
energy needs in an environmentally-friendly way
Basic Mechanisms of Solar Energy Conversion1
Fuel
Light
Electricity
Fuels Electricity
CO2 O2 H2
e e
Sugar
sc M sc M
H2O
H2 O
O2
Photovoltaic
(PV) cells Polycrystalline Si
provide O2 H2 technology in
efficiencies as e semiconductors is
low as 25% relatively complex.
Require: New sc M
electrolytes and Flat Plate Si crystalline
catalysts to H2 O is better but yet
improve efficiency significant development
of the PV cell will be required
Semiconductor/Liquid
Junctions/Photovoltaic
Steam
Heat gives
Exchangers energy to
the turbine
Fission
zone in
the
reactor
Recycling
of steam
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
… Particularly in recycling of Spent Fuel
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Not Either Or, it is all about Unification
A D
H2 H2
Electrolizer CH4 Reformer
O2
B E
H2
Methanol
Sun’s
Rays Electrolizer
Biomass
O2 Direct Methanol Fuel Cell
Photovoltaic Cells
Ethanol
C Specialized Applications F
H2 Cylinder Metal Hydride
H2
O2 Cylinder Nuclear
H2 Tanker /Pipeline
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Fuel Cells works by converting chemical energy to
electrical energy On Demand
Basic Mechanism of a Fuel Cell1
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Fuel Cells have been around since the 19th century:
Could we take on the Challenge of commercialization ?
Major Challenges in Using a Fuel Cell1,2,3
O2 Fuel
H2O
H2 /CH3OH Cell
Chemical engineers can
experiment with different materials
Size and weight of fuel cells
Heat and electrode systems to come
Process Intensification to reduce size
up with cost-effective solutions
and weight of cell
Boston Analytics Research
1. www.howstuffworks.com
2. “Changing the way America drives: WPI chemical engineer works on fuel-cell power”, WPI News & Events
3. http://www.eere.energy.gov/hydrogenandfuelcells/fuelcells/fc_challenges.html
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Heat Mining: Health & safety concerns due to materials
ejecting from the Earth are issues that will need attention
Challenges in Harnessing Geothermal Energy1,2,3,4
The steam coming out needs to
be purified before it drives the
turbine
Chemical engineers can design
a steam purification plant
Challenges of Nano-Manufacturing1,2,3
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Shape Memory Alloys (SMAs) are materials that can
recover from strain when they are heated above a certain
temperature
Basic Mechanism of SMAs1
5,544
Solar 41.1 4,053
Hydro 24.4 3,390
Biomass 12.5
910
Oil 11.0
Wind 9.9 1,363
Coal IGCC 7.1
Different methods of 1,842
Coal CFB 6.3 generating electricity from coal 1,345
Coal PF 6.1
1,511
Nuclear 4.1
2,118
Note : *These are only indicative figures. Actually, electricity generation cost varies across different
territories as per the environmental and technological scenario.
Boston Analytics Research
1. “The Cost of Generating Electricity”, Royal Academy of Engineering, March 2004 (213.130.42.236/wna_pdfs/rae-summary.pdf)
2. “Powering the Nation”, Parsons Brinckerhoff Ltd, March 2006 (http://www.pbpower.net/inprint/pbpubs/powerthenation/powerthenation.htm)
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
3. “Solar Energy in SGM, Renewable Energy Modeling Series”, Allen Fawcett, December 2004 (http://www.epa.gov/cleanrgy/pdf/fawcett-
d 6 df)
The Essential Points:
1. Indeed Challenging & Interesting times
ahead
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
We have the tools: We need the commitment
to link Supply and Demand
Supply-Demand Dynamics
Supply-Demand
Supply Demand
z Clean
z Clean Energy
Energy
z New
z New Materials
Materials
z Six
z Six Sigma
Sigma Power
Power
z Precision
z Precision Controls
Controls
z Efficiency
z Efficiency of
of
z Nanotechnology
z Nanotechnology
Consumption
Consumption
z Life
z Life Sciences
Sciences
z Ecological
z Ecological balance
balance
z Miniaturization/Process
z Miniaturization/Process
z More
z More advanced
advanced living
living
Intensification
Intensification
and
and work
work spaces
spaces
z Convergence
z Convergence // Broadband
Broadband
z Global
z Global Equity
Equity
infrastructure
infrastructure
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The Chemical Engineer is a multi-disciplinary
engineer a Strategic Problem Solver
Transport Thermo-
Phenomenon dynamics Kinetics
Materials
Biology/Genetics The Chemical Engineer Science
Computer Science
as Σ, O, H Management/Economics
Fields of
Application
80%
10%
40% improvement
20%
0%
Lighting IC Engines Air Heaters Boilers
Devices Conditioners
Equipments
0.11 0.05
0.06
Source: Technology Roadmap for the 21st Century Truck Program (DOE 2000), RMI analysis
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Reduction in energy intensity could reduce
world energy demand by 14% to 20% in 2025
World Energy Demand in Quadrillion Btu (2025)1 :If Energy Intensity is Reduced in
Selected Regions
645.0 10.3
Quadrillion Btu
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The New horizons…
Alternative Energy
Ecology friendly, Sustainable and
Safe Energy for all
Taking a bottom-up approach to manufacturing
Nano-Manufacturing mechanisms at nanoscale to yield products of high
quality with zero wastage
Novel Materials
Efficiency of Usage of Materials e.g. Shape
memory alloys, new fibers etc.
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
… beyond current framework of plant design and
engineering
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Last 5,000 Years… …..Future Possibilities..
Economics of Linear Economics of Closed
Mechanics: Extraction, Loop Harmony
Exploitation & Experimentation
Solar , Wind
Bio Mass Fuel Cells
Agro
New Energy
Clean and Power
Water Technologies
Broadband
Clean Energy
Knowledge for
Recovery/Recycle
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
.. Chemical Engineering Education & Industry
has to Rekindle the Sprit of Enquiry
High
“Renewability”
intensity
“Reconfigure”
Current processes
Low
Low High
Conservation
intensity
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
The Journey forward . . .
Toward a New
Integrated Vision
for Intelligent
Holistic “Mass &
Energy Balance”
Plays
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
It is not in the Seeming , it is in the being,
….but even more in the Becoming . . .
Lets wish for the best
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.
Questions ???
Copyright © 2006 Partha S. Ghosh & Boston Analytics. All rights reserved.