01. Process Constraints

Engineering is rarely about the perfect solution; it is about the optimal compromise. My work focuses on bridging the gap between bench-scale theory and pilot-plant reality. I approach chemical systems with a fixation on reliability, seeking to minimize variance before maximizing output.

I build systems that fail safely. Whether designing control loops for high-viscosity fluids or auditing safety protocols, I prioritize the longevity of the equipment and the safety of the operators above theoretical yields.

  • → Safety is a design input, not a checklist.
  • → Redundancy reduces panic.
  • → If you can't measure it, you can't control it.

02. Unit Operations & Tools

Process & Design

  • Aspen Plus / HYSYS [Adv]
  • PFD & P&ID Development
  • Mass & Energy Balances
  • Heat Exchanger Design

Ops & Safety

  • HAZOP & LOPA
  • PSM Awareness
  • Root Cause Analysis (RCA)
  • SOP Generation

Data & Analysis

  • Python (Pandas/NumPy)
  • Minitab / Statistica
  • Techno-Economic Analysis
  • Data Visualization

03. Case Files

Continuous Flow Reactor Optimization

Reduced residence time variation by 15%

Objective

Transition a batch synthesis process to a continuous flow reactor to improve throughput.

Approach

Modeled kinetics in Python to determine optimal tubing diameter and length. Implemented static mixers to improve heat transfer coefficients.

Result

Achieved steady state in 12 minutes with a 15% reduction in residence time variance. Yield increased by 4% due to better thermal control.

Constraint:

Pump limitations required ΔP < 4 bar.

Next Step:

Investigate inline IR spectroscopy for real-time QC.

Solvent Recovery System Retrofit

Recovered $45k/yr in raw material costs

Objective

Design a condenser loop to capture fugitive VOC emissions from a drying oven.

The Trade-off Simulation

Adjust the slider to see the impact of cooling temperature on energy cost vs. recovery rate.

Temp (C) -10
Recovery 85%
Energy Cost Medium

Balanced operating point.

Key Metric:

ROI realized in 8 months.

Automated Inventory Level Monitoring

Eliminated manual dipping and exposure risk

Objective

Replace manual dip-stick measurement for corrosive acid tanks to improve operator safety.

Approach

Selected ultrasonic level sensors compatible with PTFE lining. Integrated 4-20mA signals into existing DCS for high-level alarms.

Safety:

Zero operator exposure events post-install.

04. Field Log

2024 — Present Global Chem Co.

Process Engineer II

  • Lead engineer for the expansion of Line 4, managing a capital budget of $250k.
  • Updated P&IDs for 30+ subsystems ensuring compliance with OSHA PSM standards.
2021 — 2023 Midwest Polymers

Junior Chemical Engineer

  • Conducted mass balance audits reducing raw material waste by 3%.
  • Assisted in the commissioning of a new extrusion line.

05. Lab Notes

Oct 12 On the fallacy of "Zero Risk" in Process Safety

We often conflate 'safe' with 'zero risk'. In thermodynamics and in operations, zero is a theoretical limit, not an operating point. The goal is ALARP (As Low As Reasonably Practicable).

Aug 04 Scale-up factors: Linear isn't real

Surface-area-to-volume ratios change drastically from flask to tank. Cooling capacity that works at 1L is usually insufficient at 1000L without jacket modification.

06. End of Line

Available for process engineering roles and consultancy.

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