Introduction to Chemical Product Design(ENCH600023, ENBP600014: 4 SKS) Capstone CoursePREPARING FOR ENGINEERING PRACTICEKnowledgeSkills2014

InstructorsProf. Widodo W. Purwanto (WD)Dr.rar.nat. Yuswan Muharam (YM)Prof. Dr. Misri Gozan (MG)Dewi Tristantini PhD (DT) Assistants: Muthia (Koordinator)Haisa YuaraLaras NovitasariSesilia GenesyM. Ilham ChairatOlivia Cesaran

Course OutcomesMahasiswa 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 Syllabus and Design Topics Chemical Industry Trend Chemical Engineering DesignTrends Chemical Product Design

Chemical Industry Trend

Major development of ChE

Expanding the scope in ChE

The Promise of Chemical Industry -Multiple Scales2008 Partha S GhoshScales of EngagementHolistic /Tera Scale PerspectiveMicroscopic Perspective Three Scales of Knowledge ApplicationLarge Scale Systems Dynamics Issues Global Ecological Balance ? Energy Balance ? Social Structures ?Raw materialsCellular /Nano Level functionalitiesTera ScaleCurrent ScaleMicro Nano Scale1. Efficiency 2. Conservation3. Recycling123Socialization Process of Multiple disciplines

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 IndustryDesign of chemical products beginswith the identification and creation ofpotential opportunities to satisfysocietal needs and to generate profit

Process operation for 3 types of chemical products

Chemical Product TreeSource: Gani, 2004Purity/compositionPerformance

Chemical engineers &products

Trend affecting new product strategies in the chemical industry

Chemical Commodities vs. ProductsCommoditiesCompositional spec GenericLow marginHigh volumeProcess-centeredProductsPerformance specDifferentiatedHigh marginOften low volumeProduct-centered

Process-Centered Company to Product-Centered CompanySource: Stephanopoulos, 2004

Source: Stephanopoulos, 2004

Source: Stephanopoulos, 2004

Typicals companiesUnileverP&GDowMerckLOrealIndofoodKalbe FarmaNestleMartha Tilaaretc

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 DesignGani, 2009

Similarities & DifferencesProcess DesignProduct is specified but process is notFocus on models of manufacturing processSearch technique to select among process alternativesGoal is lowest cost manufacturing processProduct DesignNeither product nor process is specifiedFocus on models of product propertiesSearch technique to select among product alternativesGoal is added value through enhanced product properties

Chemical Process vs. Product Design

Process DesignProduct DesignBatch vs. Continous ProcessIdentify Customer NeedsInputs and OutputsGenerate Ideas to Meet NeedsReactors and RecyclesSelect Among IdeasSeparation and Heat IntegrationManufacture Products

Chemical Product Design

Why CPD Is Important

Changes in the Chemical IndustryChanges in EmploymentChanges in Corporate Culture

Trend affecting ChE employmentCussler & Wei, AIChE J, 49 1073

Chronological of chemical product engineering as a discipline within chemical engineering

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

What is CPD?

Typical product forms and ExamplesMoggridge, 2006

Relationship between system composition, processing and product functionBroekhuis, 2012

Formulated products: dispersed microstructured materialsBroekhuis, 2012

Process-Property-Processing RelationsBroekhuis, 2012

Chemical Product PyramidMoggridge, 2006

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

Classification of product development activities by phase and by taskCheng, 2009

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 Design Procedure

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

Time value of moneyQuantitative measures of profitabilityEstimation of costsSystematic comparison of alternativesEngineering Economics

Entrepreneurship

Component of Innovation Ecosystem

Technology S-curve

Three economic objectives for entrepreneurshipEntrepreneur is individual whose function is to create new combinationsof ideas, products and markets for an economy

Enterprise and business market relationship

Ralating Sectors of Economic objectives

Place of the Designers

Teamwork

Thank You

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