This course introduces you to chemical engineering and shows you how common industrial processes such as Steam Methane Reforming, Steam power plants, Cracking of Ethane, Purification of ethanol and several other processes can be simulated using a process simulation software.
Process simulation is a much needed skill in the Oil & Gas, Chemical, Petrochemical and Energy industry. Build Industrial Chemical Processes right there on your computer and see what effect a change in some of the Process Conditions would have on the yield of the process.
This is a fully hands on course.
How the course is set
This course is designed for anyone with a little knowledge of Chemistry and an interest in Simulation of Industrial Chemical Processes. Each section has lectures dedicated to covering the required theoretical background to the course and also has screen videos to show how the process of interest is simulated using the COCO process simulator software. We would not just discuss chemical processes, you would actually build these processes by yourself.
External resources such as video animations, YouTube videos and Wikipedia pages which would make the concepts taught easier to understand are also included in the external resources section. Since this course is designed to give you a practical skill which you can use in the workplace, there are lots of quizzes which gauge your ability to use the software.
The first section teaches some of the basic concepts you would need to be able to model chemical processes such as an Introduction to Chemical engineering, Unit operations and the Concept behind process simulation. The lecture which covers thermodynamics would be coming soon.
The second section shows you how to get your PC set up for this course.
The remaining sections of the course focuses on using the process simulation software COCO to model various chemical processes in a hands on manner.
This lecture serves as an overview of Chemical engineering and sets the foundation for the rest of the content in this course.
The entire series of lectures is centred around process simulation. This lecture explains what chemical process simulation is.
This lecture gives an overview of Chemical engineering Unit operations. Unit operations are explained using the human body as a case study and also the production of Di-ethyl ether.
The external link contains information about the uses of Di-ethyl ether.
This is a short article which discusses the need for recycle in chemical processes. An external link which discusses recycle in chemical processes is also attached.
COCO is a free process simulation software, and is the central software for this course. This lecture discusses what COCO is and what it's capabilities are.
This screen video show you how to download COCO from the developers website.
COCO works perfectly well on Windows OS, this lecture shows the installation process.
This lecture shows how to start COCO and how to carry out some basic operations in the COCO interface.
The pdf document in the resource section of this lecture shows how you can carry out the basic tasks in COCO.
This lecture gives an overview of what a steam power plant is, and sets the tone for the simulation which you would be expected to build at the end of this section.
Compressors and expanders are a common piece of equipment in most process plants. This lecture discusses the role compressors and expanders play in the chemical process industry.
This is a screen video lecture which shows how a compressor can be modelled in COCO. The problem statement is shown below:
Saturated water vapor at 100Kpa (99.63°C) is compressed adiabatically to 300Kpa. If the compressor efficiency is 0.75 and the steam flows at a rate of 10kg/s. What is the work required and the properties of the discharge stream?
An expander was simulated using COCO in this lecture. The problem statement is shown below:
ÒA stream of ethylene gas at 300˚C and 45bar is expanded adiabatically in a turbine to 2 bar. Calculate the isentropic work produced.
This quiz tests your ability to model an expander in COCO.
If the flowrate of ethylene into the expander in the previous screen video was increased to 20Kg/s (from 10Kg/s), and all the parameters remained the same (inlet pressure of 45bar and inlet temperature of 300*C and isentropic efficiency of 1). How would the outlet condition of the gas change?
This is a lecture focused on the pump as a process equipment. It discusses the types of pumps which exist and also the real life application of pumps. At the end of this lecture, a problem statement which would be solved using COCO was highlighted.
This is a short screen video presentation which shows how a pump unit operation can be added to a process simulation model.
This quiz tests your understanding of how to simulate a pump using COCO.
Heat transfer is a very important concept in the process industry. Heat transfer equipment are of various types including heaters, coolers and different types of heat exchangers.
Please check the resource section in this lecture for a guide on how to simulate the steam power plant.
This video shows how the Steam power plant process can be simulated using COCO. You are advised to try to simulate the process by yourself first before watching this video.
A power plant generates 90Kg/s of steam at a pressure of 86bar and a temperature of 773.15K,
this steam goes through an expander which converts the fluid internal energy into rotational
energy which is used to turn generators and produce electricity. The discharge from the expander
enters a condenser at a pressure of 100KPa where it is converted to saturated liquid. The
condenser removes energy from the process stream at a rate of 7.287×108KJ/h, in order to
change the expander discharge into liquid. A pump pressurizes the liquid leaving the condenser
to a pressure of 86bar and sends it to the boiler which converts it to steam at a temperature of
500C for power generation.
If the efficiency of the expander and pump is assumed to be 75%, what amount of energy would
be produced from the plant through the expander?
What would be the energy requirement of the pump?
What would be the heat duty of the reboiler?
This lecture is focused on chemical reactions and the type of chemical reactors commonly used in process plants. The design equation for a CSTR, PFR and a BR are all stated. This lecture covers the needed theoretical basis required so that chemical processes which involve chemical reactions can be properly modelled.
This screen video models a conversion reactor needed in the oxidation of methane.
Hydrogen is an important fuel used in several processes. Hydrogen gas is produced from hydrocarbon by oxidizing with air. The reaction would be modeled as conversion reactions in COCO.
This lecture demonstrates how a Plug Flow Reactor can be modeled using the cracking of ethane as a case study.
Pure Ethane at a temperature of 298.15K and pressure of 1 bar is compressed to 4bar and heated to a temperature of 998.15K before it is fed into a plug flow reactor. Ethane decomposes at this reaction condition to ethylene and hydrogen. The decomposition reaction is first order with respect to ethane with rate constant 0.2533s-1 (3), if the molar flow rate of ethane into the reactor is 16.67mol/s, and the reactor tube diameter is 0.0706m and has a length of 100.2m, what is the pressure of the product stream and the mole fraction of ethylene in the product stream.
A broad overview into the different types of separation processes which exist.
This lecture takes a great leap into distillation, it was designed to demonstrate the concept of distillation.
A mixture of ethanol and water (Ethanol 37%, Water 63%) at a temperature of 25*C and pressure of 101.325KPa is fed into a distillation column. The distillate is expected to come out with 83% ethanol and 17% water while the bottom should contain nothing more than 10% ethanol.
If the column is modelled using 20 stages, what would be the flowrate and process conditions of the distillate and bottoms?
The distillation process is examined in this screen video.
´Carbon dioxide from a fermentation process at a pressure of 2atm and a temperature of 25ᵒC contains 30 mol percent ethyl alcohol. The alcohol needs to be removed by contact with water at 25*C and 2 atm. The gas flow rate is 400 lbmol/h and that of the water stream is 2000 lbmol/h. Determine the compositions of the streams leaving the absorption column if you model it with 10 stages, and what is the amount of ethanol recovered?
The result of the gas absorption process is examined in this lecture. The component splitter unit operation is also added to the flowsheet.
This article explains the basic chemistry behind the di ethyl ether production process.
The property package and reaction package is set up in this lecture. The conversion reactor required for the process is fully set up.
At this point, the reactor has been fully modeled. The reaction product mixture contains ethanol, water and di ethyl ether. These mixture needs to be separated using two distillation columns. the first of these columns is added to the flowsheet in this lecture.
The second column is added to the flowsheet and also a recycle stream.
This lecture is about the Haber process, it explains the chemistry behind the process and also explains the reason for the choice of the process conditions.
This article gives a general overview into Steam Methane Reforming process.
The modeling of the SMR process begins here. In this lecture, the property and reaction package are defined. The reactant preparation steps are also shown along with the addition of the equilibrium reactor to the flowsheet.
The shift reactors are added to the flowsheet.
This brings us to the end of the modeling of the Steam Methane Reforming process.
This lecture shows how the air separation flow sheet is downloaded from the COCO developers website.
This lecture gives an overview of the air separation process.
This lecture gives a brief overview of the calculations we would do before simulating the Haber process.
In this lecture, you would learn how to add sub flowsheets. The air separation sub-flowsheet would be added into the haber process simulation.
The Steam methane reforming process is added as a Sub-flowsheet in this lecture. Both hydrogen and nitrogen streams are prepared for the Haber process.
The gibbs reactor was added in this lecture and the ammonia product was separated.
I hold a degree in Chemical engineering from the University of Lagos with extensive experience in the field of Process engineering. My expertise in Process engineering extends from working as a Facilities Engineer in a Natural Gas Plant, to working as a Process Design Engineer in a leading Engineering design firm.
At the moment, I am a graduate student of Subsea Engineering at the University of Houston with research interests in Subsea processing and design of Subsea equipment.
I am passionate about teaching, I have taught process simulation to lots of undergraduate students over the past three years.
I belong to a team- Spunt Innovatia which is committed to delivering excellent engineering training to people around the world. We believe in providing people with the necessary engineering skill set they need to succeed at their career.
The course 'Simulation of Chemical engineering processes using COCO' was a spin off from a project that was started by the faculty members (Dr. Daniel Ayo, Dr. Tolu Ajayi and Dr. Akinjide Akinola) of the Department of Chemical engineering at the University of Lagos.
I hope you enjoy the course just as much as I enjoyed putting it together.