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Introduction to Chemical Product Design

Capstone Course

PREPARING FOR ENGINEERING PRACTICE

Innovation
Knowledge Skills

2018
Course Outcomes
Mahasiswa mampu menggunakan pengetahuan yang
didapat dari beberapa mata ajaran sebelumnya pada
disain produk kimia secara lengkap yang meliputi:
Needs, Ideas, Selection, Manufacture, Supply Chain,
HSE, dan Economics.
Mahasiswa memiliki kemampuan pemecahan masalah
dan bekerja dalam tim.
Mahasiswa memiliki kecakapan sebagai wirausaha.
Course Content

Course Outcomes
Chemical Industry Trend
Motivations
Chemical Engineering DesignTrends
Chemical Product Design
Chemical Industry Trend
Major development of ChE
Expanding the scope in ChE
The Promise of Chemical Industry -Multiple Scales

Three Scales of Knowledge Application


Holistic /Tera Scale
Perspective
Large Scale Systems Dynamics Tera Scale
Issues s
1 • Global Ecological Balance ?line
• Energy Balance ? c ip
s
• Social Structures ? di
le
Scales of Engagement

ti p
ul Current
M
of Scale
2 e ss
oc
1. Efficiency
P r 2. Conservation
n 3. Recycling
Raw materials tio
a
l iz
c ia
So Micro Nano
Cellular /Nano Scale
3 Level
functionalities
Microscopic
Perspective

2008 © Partha S Ghosh


Role of ChE
From “Bulk” to “Molecular” Processing
Raw Materials to Consumer Products
Chemical Product Types
Scope of
Chemical Product and Process Industry

Design of chemical
products begins
with the
identification and
creation of
potential
opportunities to
satisfy
societal needs and
to generate profit
Chemical Product Tree

Performance

Purity
/composition

Source: Gani, 2004


Chemical engineers &products
Bulk vs. Fine Chemicals
FINE CHEMICALS: these are chemicals made on small
scales and high quality chemicals used in flavour,
fragrance, tobacco, foundry, agro-chemical and
pharmaceutical and other industrial applications.

BULK CHEMICALS: these are chemicals made on large


scales (thousands or millions of tonnes a year), such
as ammonia, sulphuric acid, sodium hydroxide,
chlorine and ethene.
Chemical Commodities vs. Products
Commodities Products
Compositional spec Performance spec
Generic Differentiated
Low margin High margin
High volume Often low volume
Process-centered Product-centered
Process-Centered Company to
Product-Centered Company

Source: Stephanopoulos, 2004


Source: Stephanopoulos, 2004
Source: Stephanopoulos, 2004
Perubahan rantai nilai industri kimia
Perubahan rantai nilai industri kimia

Source: MCE
Trend affecting new product strategies
in the chemical industry
Global Top 10 chemcal industry

Source: CEN, ACS


Fast moving consumer goods
Trend affecting ChE employment

Cussler & Wei, AIChE J, 49 1073


Chronological of chemical product
engineering as a discipline within
chemical engineering
Motivation
Trade specialization index

Source: ABD, 2014


Kontribusi GDP dan pertumbuhan mengalami
penurunan

Source: OECD, 2015


Knowledge-economy index
Education and skill

Innovation

Source: ADB, 2014


Industry 4.0

• Horizontal integration
via new generations of
Global Value Chain
Networks.
• Vertical Networking of
Smart Production
Systems.
• Consolidation of new
technologies.

“A collective term for technologies and concepts of value chain organization’ which
draws together Cyber-Physical Systems, the Internet of Things and the Internet of
Services.”
Industry 4.0 for chemical Industry
Chemical Engineering
Design Trend
What is engineering design?
The process of applying various techniques and
scientific principles for the purpose of defining a
device, a process or a system in sufficient detail to
permit physical realization.
The design engineer makes choices based on a
thorough understanding of the engineering
fundamental, feasibility constraint, reliability, cost,
manufacturability, and human factors.
Good design requires experience, knowledge and
a considerable amount of intuition.
Product and Process Development
Design Objectives
determine the goal
determine all relevant factors
see the “big picture”
focus on critical issues
economic objective function + ecological,
social
Characteristic of Design
Emphasis on synthesis, analysis & evaluation
Creative, Interactive and Iterative,
Problem statement ill-posed and open-ended,
Team-oriented and multi-disciplinary,
More than one right answer,
improve or new chemical product,
Always performed with an eye toward
the ultimate benefit, generally economic.
Design Thinking Framework
New Approach of Design

Gani, 2009
Similarities & Differences
Process Design Product Design
Product is specified but Neither product nor process is
process is not specified
Focus on models of Focus on models of product
manufacturing process properties
Search technique to select Search technique to select
among process alternatives among product alternatives
Goal is lowest cost Goal is added value through
manufacturing process enhanced product properties
Chemical Process vs. Product Design

Process Design Product Design

Batch vs. Continous Identify Customer


Process Needs
Inputs and Outputs Generate Ideas to
Meet Needs
Reactors and Select Among Ideas
Recycles
Separation and Heat Manufacture Products
Integration
Chemical Product Design
Why CPD Is Important

Changes in the Chemical Industry


Changes in Employment
Changes in Corporate Culture
What is CPD?
New specialty chemicals that provide a specific
benefit, i.e. Pharmaceuticals

Microstructures of product, rather than


molecular structures, creates value: processed
foods, household products, personal care
products i.e. Paint and Ice Cream, margarine,
shampoo, toothpaste,

Devices that effect chemical changes, i.e. Blood


Oxygenator in Open Heart Surgery
Typical product forms and Examples

Moggridge, 2006
Relationship between system composition,
processing and product function

Broekhuis, 2012
Formulated products: dispersed
microstructured materials

Broekhuis, 2012
Process-Property-Processing Relations

Broekhuis, 2012
Chemical Product Pyramid

Moggridge, 2006
Concepts of Property Function, Process
Function and Usage Function

Moggridge, 2006
Classification of product development activities by phase
and by task

Cheng, 2009
The Product Design Procedure

Needs  What needs should the product


fulfill ?
Ideas  What different products could
satisfy these needs ?
Selection  Which idea are the most
promising ?
Manufacture  How can we make the product in
commercial quantities ?
The Product Developmet Procedure

Cheng, 2009
The Industrial Design Process
Product Development Process
Customer Needs Process
Source: Hey et al, 2006
Product Specification
Product Specification
Idea/Concept Generation
Concept Selection

• The goal of concept selection is not to


select the best concept

• The goal of concept selection is to


develop the best concept.
Manufacturing
Engineering Economics
Time value of money
Quantitative measures of
profitability
Estimation of costs
Systematic comparison of
alternatives
Entrepreneurship & Innovation
What is entrepreneur

An entrepreneur is a starter, an initiator, a


chellenger and adriver,
Someone that creates something new,
either an initiative, a business or a
company,
He or she is is the biginning of a venture,
project or activity.
Component of Innovation
Ecosystem
Technology S-curve
Three economic objectives for
entrepreneurship

Entrepreneur is individual whose function is to create new combinations


of ideas, products and markets for an economy
Ralating Sectors of Economic objectives
Place of the Designers
Thank You

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