When talking about refinery, we need to be able to differentiate and identify an oil refinery from the edible oil refinery. Basically, the oil refinery (or petroleum refinery) is an industrial process plant where crude oil (from crude petroleum) is processed and refined into more useful petroleum products, such as gasoline, diesel fuel, asphalt base, heating oil, kerosene, and liquefied petroleum gas. This is the type of refinery mentioned in the 13 Days: Pythagoras Conspiracy Novel. An edible oil plant in the other hand, is almost similar to the earlier refinery accept it processes edible oil and involves the removal of fatty acid and a few more unwanted impurities. The edible oils are obtained from the likes of palm oil, soya bean oil, canola oil, corn oil, rape seed oil and others. In other words, the oil refinery process oil that cannot be consumed by human being while the edible oil refinery process oil that is edible (can be consumed by human beings).
I have no direct involvement in the oil refinery. However, I was a process engineer in an edible refinery plant before for quite some time. I had a really good taste of experience working in the refinery plant before. I strongly believe that if a chemical engineering student or a new chemical engineer wants to gain experience, he or she should work in a refinery. This is mainly because they will learn and apply all that they have learn in chemical engineering.
Edible Oil Refinery
Edible oil originates from crude oil such as crude palm oil (CPO), crude soya bean oil (CSBO), crude rape seed oil (CRSO), crude coconut oil (CCO) and so on. Edible oils have very high content of free fatty acids (FFA) and needs to be refined before using as cooking oil. However, the refinery process isn't only limited to remove FFA, it also removes the undesired components such as moisture, color and odour which may trigger negative impact on the final taste, odour and appearance of the oil product. The resultant oil is thinner without fatty acids, colorless and odorless.
It is imperative to note that the edible oil refinery can be divided into 2 primary types namely, chemical refining and physical refining. This time, I'll explain about the chemical refining plant. Chemical Refining Plant
Chemical refining plant involve neutralization of crude oil by removing fatty acids. This is always referred to as chemical refining or sometimes Neutralizing process and its plant referred as Neutralizing Plant (NP). In this process the oil is neutralized in the neutralizer to remove the fatty acids by mixing with caustic soda (sodium hydroxide). Oil is heated up to roughly 60oC by and oil is stirred by stirrer. The fatty acids are settled at the bottom as alkali soaps which is called soapstock from where it is taken out into soap tank .
Typical Neutralizing Plant. Image credited to Oiltek Sdn Bhd, a Malaysian company that manufactures edible oil equipments.Click on the photo to enlarge it.
Removal of impurities and color
Neutralized oil is passed through the second vessel called bleacher where color of oil is removed by bleaching process with the help of chemicals such as carbon black and bleaching clay. Oil is usually heated up to 110oC. Stirring is also carried on. Bleaching process is done under vacuum. Bleached oil then goes to filtration process where bleaching clay and chemicals are removed and cleaned.
Removal of unpleasant smell
Bleached oil is then passed through deodorizer where oil is heated above 110C and then live steam clean is used to the oil from the bottom steam nozzles. The temperature of oil is raised up to 200 to 220C through thermic fluid coils. Entire process is done under high vacuum. Thus smell is removed from the oil in the deodorizer. Then it goes to cooler where cold water circulating coils take away heat and oil is cooled.
Final Filtration
Final filtration is performed after cooling down the oil. This operation is carried out in a micro filter closet or filter bag/filter cartridge which makes the final edible oil termed as refined edible oil. This final filtration process is designed for more effective filtration and best quality of final refined edible oil. There are certain refineries that adopted Hazard Analysis Critical Control Point (HACCP) to completely ensure that the oil is free and safe to be consumed.
This is a typical physical refinery plant. The image is also credited to Oiltek. Click the image to enlarge it.
In the next post, I'll describe more about the Physical Refinery. This is where I gained the most of my hands on chemical engineering experiences. This is where I learned more about important unit operations such as heat exchanger, cooling tower, deodoriser, pack coloumn etc.
Update: As a process engineer or production engineer in a plant (such as this chemical / physical refining plant), you need to know, be prepared and keep stock of all spare parts and engineering equipments (especially during shut downs or turn around). WDS Component Parts has been quite helpful in that area. They supply a vast array of top quality parts, and their website is really cool because it is easy to navigate – which is especially useful when you’re looking for something particularly obscure.
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Last December, my wife participated in a Scientific Publishing Research Workshop in Shanghai China from 20-22 December 2011 to present her technical paper about Progressive Freeze Concentration (PFC). The research is directly related to her own Ph.D and her present core research. I accompanied her to Shanghai and at the conference I joined as a participant.
The workshop is not specifically tailored to chemical engineering only. It combines chemistry, biochemistry, maths and several other disciplines. I can say it is a highly multi-disciplinary workshop. The participants came from all over the world including United States, German, Japan, India, China, Greece, Korea, Malaysia and others.
The President of Scientific Research Publisher (SciRP) giving his speech.
Some of you might have not heard about Scientific Research Publisher (SciRP) while some probably have heard about it. SciRP is an academic publisher of open access journals. It also publishes academic books and conference proceedings. SCIRP currently has more than 150 open access journals in the areas of science, technology, and medicine.
SciRP actually provides an alternative means of scientific research publication. The difference is only it is practices an open access system where anybody can read the journal free of charge. The other traditional journal from publishers like Elsevier require us to pay before we can read them. However, as students, most of us can have access to it because our university library have purchase the subscription from the publisher. Hence, we are open to write and submit to SciRP. The process is almost the same. The draft paper will be evaluated by editors and undergo strict requirement to ensure top notch quality of the article.
As for us Chemical Engineers, the most related journal is Advances of Chemical Engineering & Science. The journal is relatively new but is good enough for us to submit articles to them. Once thing to know about open access journal like this is that some fee will be charge to the publisher.
That's me (left) behind sitting next to my wife. The two gentlements on the right are professors from India. The woman in front is a researcher from Greece.
Among the participants of the 1st Scientific Research Publishing workshop.
My wife presenting her technical paper. However, before she proceed with the presentation, she explained briefly about Universiti Teknologi Malaysia (UTM) and also Malaysia.
This is the panoramic scene outside the workshop room. The hotel where the workshop took place is situated in a resort style hotel. The view is actually part of a golf course. The temperature in Shanghai at this time is between 0-6 Celcius.
This is another view of the peaceful scenery outside the workshop room.
Lunch break. We were served with 10 course local Chinese dish. Frankly, the food is very different than what we usually have. Nevertheless we tried to eat some of the uniquely served dishes.
That's me in front of the hotel lobby where the workshop takes place. Check out the red banner on the top of the hotel lobby building. This is proof that this is the first SciRP workshop.
Overall, it was a very interesting experiences attending the 1st Scientific Research Publishing Workshop. I was really honoured to meet the founder and president of SciRP as well other professors, academicians and researchers from other parts of the globe. Besides expanding our knowledge we get the chance to meet new people and increase our networking (which is important in the real world).
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I was approach by Mr Chikezie Nwaoha, a friend from Nigeria and also a Downstream Correspondent of Petroleum Africa Magazine. He is also a Contributing Editor for Control Engineering Asia Magazine and Contributing Editor for PetroMin. Somewhere last year, if I'm not mistaken in July 2011, he emailed me with intention to interview me about cooling tower. The reason for this is because previously I have co-written a book chapter with him about Cooling Towers which will published in a book titled 'Process Plant Equipment Operation, Reliability and Control'. The book which is published by John Wiley will be ready this coming May 2012. I'm so excited and cannot wait to get my hands on this new book. My contribution is in Chapter 5.
Instead of the topic cooling tower, I said why not you interview me about Plate Heat Exchanger because it is my favourite equipment. Well, he said yes. He can interview me about Plate Heat Exchanger. Well, the interview when well and it was published soon in November 2011 in the Downstream Focus section in Petroleum Africa Magazine page 30-33 (4 pages).
- Please click the photo to enlarge -
I'm not sure if I'm allowed to place the interview article here. If I have the permission, I'll make it available for download.
Here is a partial shot from the 3rd page.
- Please click the photo to enlarge - I hope I can contribute more like this in future. If you want to read Petroleum Africa Magazine, you can try it out and subscribe it here.
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I have not able to post about this story last week. Well, last Friday, I received a letter from the Board Of Engineers, Malaysia (BEM) stating that I have been appointed as a Professional Engineer, a status I believe is equal to Chartered Engineer from United Kingdom (that I received several weeks ago).
After 4 years of effort, finally I managed to be a Professional Engineer which allows me the title "Ir." in front of my name and also "PEng" after my name. This is an achievement that I'm very glad to received. It's not just the privilege of having the title but it also impies that I have to carry more responsibilities. As a professional engineer in the discipline of Chemical Engineering, I need to show good professional engineer example, promote ethical engineering practice, help and guide those who want to be professional engineer and many other roles. The society and community will be looking and referring to us on certain matters. A professional engineer also need to contribute as much as humanly possible to the engineering society.
As a first step towards helping others to attain professional engineer or chartered engineer status, I have thought of preparing a short report of my experience on my journey to be both professional and chartered engineer. I am wondering whether there will be a demand for this report? What do you think? Should I prepare such experience sharing report?
In order to have better comprehension of the situation, I have prepared a short 10 question simple survey for you to answer. The answers will help me understand and hopefully prepare a good comprehensive guide on how to assist you in getting Professional Engineer or Chartered Engineer status. Please help me answer the survey >>> HERE <<<.
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In the early morning of yesterday, I noticed one email from Karen Brown of IChemE which I read from my Samsung Galaxy Ace Mobile phone (not iPhone). I was very anxious to read her email because the title of the email stated "IChemE Application to transfer to Chartered Membership". I scanned the email swiftly and later read it word by word. Yes! The result from the interview in August is out and I'm now accepted as a member of IChemE and Chartered Engineer. This is the beginning of my professional career as a professional engineer under IChemE.
Among the interesting massage obtained from the email was that I am now eligible to use designatory lettersMIChemE after my name. In addition, I am also eligible to use the CEng designatory letters after my name too. CEng stands for Chartered Engineer. This status is given by the Engineering Council of UK.
Based on the email from Karen, I logined into my IChemE website wanting to updated my personal status. I saw that my membership status has already changed to Member Status. Everything has been automatically updated. This is so cool.
I'm now in the process of preparing the IChemE personal stamp and also waiting for the certificate.
I must say that I'm so proud to be an IChemE member. I remembered becoming an IChemE student member in 1998. Then in 2000 I upgraded the membership to Associate Member allowing me to use the designatory AMIChemE. Now in 2011, thanked God I successfully managed to be an IChemE member. Being an IChemE member, I am allowed to do some professional networking, collaborations, knowledge sharing, participate in subject groups and the one that I always use is Knovel database to read online books that is subscribe. This is mainly for my Ph.D research references.
Are you an IChemE member? If not, register now... :)
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As some of you know, I am currently a Ph.D student in my final year and at this moment I can say I am working very hard running my experiments. Why do I say so? Well, part of the reason is because I'm the earliest person to reach the lab and the last person to leave the lab for any single day (accept if I have something urgent going on). I run 1 to 3 experiments per day depending on the situation that day. Why I say this, you'll know when I list down some of the problems I face when I run my experiments.
The experiments that I or other Ph.D students run are no ordinary experiments. The experiments are not at all similar to those that the undergraduates carry out in the lab. We are running our own individual experiments for research and discovery purpose. We are seeking for new information, new knowledge, new theory, new discovery. We want to find out about something. We want to see whether this and this works or not. We want to see what will happen when we do this and this and so on. Of course, this will be based on our literature review and hypothesis. Our experimental set-up is in most case unique and not similar to others. If it is similar though, there will be perhaps 2, 3 or 4 almost similar experimental set-up. I'm referring to the experimental set-up that we create ourselves.
OK, the main thing I want to share here is the list of problems, challenges, hurdles that interrupt the process of me running my experiment. Some of the problems are as stated below.
process tubing leaks
fitting leaks
o-ring burst
gas suddenly finish
furnace suddenly cannot operate
heating tape spoil
heating tape controller spoil
reactor easily broken (quartz)
support for catalyst broken
Not enough or no liquid to collect for analysis
Gas that is collected in a container could not be analyzed
Dirty GC column
Column not suitable for our products
GC need to be calibrated
No gaseous available, need to order gaseous from company
Rota flow meter not reliable, cannot control flow of carrier gas
No mass flow controller
Vacuum fitting cannot be tightened
Data logger for temperature monitoring software has problem
thermocouple seal leak and fluid penetrate through wire and flooded the data logger
Quartz tube after experiment are very dirty and difficult to clean
No water bath, so I have to used my own condenser.
Sabotage (this happen to my colleague. Her gas tank tubings were cut).
Please be informed that I'm not listing all these problems to discourage or demotivate some of you who may consider to pursue your Ph.D with experimental work. What I'm trying to highlight here is that if you are running experiments for your research work, you will face with tonnes of challenges. You need to stay strong and motivated. You need to focus at the end result. Of course there will be some obstacles, problems, delays and many other things that will result to you feeling down. I will be lying if I say I'm always motivated. I faced numerous expected and unexpected challenges. It's really up to me to react on the problem and overcome those challenges.
In addition, during this critical time, we need to always be positive and pray to God for assistance. On top of that, when ever we have experimental problems or delays, we need to have plan A, B, C and so on which means we can do other things such as drafting technical papers, search for latest literature review, learn related softwares etc.
If any of you have some good experience to share, feel free to contact me. I would love to hear from you as well. Cheers...
OK, that's enough for now. I'll share later updates with you soon. For my fellow Muslim chemical engineers (student or practicing), I wish you Happy Ramadhan and hope all of us can be fasting with peace.
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I have wanted to write and publish about this since few weeks ago. Unfortunately I was hooked up with my Ph.D study. I'm presently running my experiments in the lab.
Well here how the story goes on my quest to be a professional engineer under the Institution of Engineers, Malaysia (IEM).
2007
I registered with IEM as a graduate member. After officially becoming a graduate member, I searched for a mentor to help and guide me to be a professional engineer. Unfortunately, I could not find any professional chemical engineer that is available to be my mentor in Johor (the state that I live and work in). So, I decided to search for any mentor in Klang Valley area. Take note that I got the list of chemical engineering mentor from IEM. To cut the story short I found a mentor which I'm attracted to and contacted him. He is Hj. Ir. Tunai Shamsidi Ahmad, a very experienced chemical engineering consultant. He agreed to mentor me and I started recording my training and experience report. My training reports were all about my activities in the plant plus several projects that I was involved in. That time I was a process engineer working in a physical refinery plant. According to my mentor, my working experiences keep repeating month after month. That, according to him is not good enough for me. I need to get involved with more projects and tasks.
2008
I resigned as a process engineer in early 3rd quarter this year and began my career as a lecturer. As a lecturer, I strongly believe I have better control of my career direction. I'm not only involved in lecturing but also research, consultancy, writing, publication and many more. It's quite an interesting experience.
My mentor was very delighted after he knew that I become a lecturer. He said by becoming a lecturer, I will have more diversified projects that I can be involved in. As a result, my training reports became more interesting. Earlier on, my training reports dwell on activities in the plant/factory. But now, I have totally new experiences that I can record in my training report.
2010
After 3 years recording my engineering training report and completed attending all mandatory trainings required by the Board of Engineers Malaysia (BEM), finally I'm qualified for the professional interview (PI) which is to be conducted by IEM. I then filled up the required forms, paid the fees and standby for the PI. While waiting for the PI, I have to prepare 2 more detail reports which are (1) Project Technical Report and (2) Training and Experience Report.
Earlier on, I had a headache thinking of what project I should write for my Project Technical Report. However, after a while I considered the Plate Heat Exchanger Installation in my plant. The project really fits all requirement and elements for the report such as design, engineering, economic, planning, project management etc.
2011
I was informed by IEM secretarial in January that my interview will take place in IEM head quarters in Petaling Jaya. Later in April, I received a call and email informing about my Professional Interview. I prepared for the interview like mad. The interview will consists of (1) oral session and (2) Essay questions which is related to our own technical project and engineering ethics.
Finally, in late June, I received a notification email from IEM confirming that I have passed my Professional Interview. Hence, my membership is upgraded to corporate member which will then be awarded the title IR (Ingeniur) by BEM (after I completed necessary paper works). Thank God I passed this Professional Interview. All the hard work has finally paid off. It was very tough to prepare the project technical report. It was like doing the final year design project alone (not in a group). But now, the project must be a real project that I have handled before. I must also thank many people for assisting me on creating my project technical report.
What about IChemE (Institution of Chemical Engineer) membership?
At the same time of preparing my project technical report, I also prepared myself to be a chartered engineer under IChemE. At this moment, IChemE representative has already emailed me and ask me to standby for the interview which will take place anytime from now. Deep inside I hope I can also make it for the interview. Wish me luck... :)
My 2 cents:- If you are not yet a professional engineer, don't wait!!! Register yourself with the engineering professional body in your country, follow the training program and record your engineering training experiences. I'm saying this because I wish somebody have advise me earlier to be a professional engineer while I'm still younger (I mean just after graduating). So, if you are in Malaysia, register with IEM. If you are in UK, register with IChemE. If you are in USA, register with AIChE. The same goes to the other countries... Good luck :)
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Once upon a time in the Chemical Reaction Engineering Research Laboratory
On a sweet Thursday afternoon (today) when I just started my experiment, a sudden power failure occurred without warning. I was actually in the toilet when the power cut off took place. My wife called and asked, "Do you have electricity there in the lab?". I answered, "We have power here in the lab and I just started my experiment". Then 2 lab assistants walk out from the polymer lab (which is next to the reaction engineering lab) and informed me that the power failure just happened. I was surprised.
Immediately I ran into the lab and discovered that the lab black out. Oh my God!!! This is not good. It's not really about my experiment. It's the Gas Chromatography (GC) which I'm more worried about. The GC is such an important equipment for me and the rest of the students as we use it to identify and quantify our products from the reactor. The GC is very sensitive and frequent power cut-off can jeopardize the equipment and interrupt our research activities. Repairing the GC cost huge amount of money and with limited research budget, we need to do everything to avoid the GC from malfunctioning.
After about 15 to 20 minutes the electrical power resumed. Thank God. I switched it on. I then checked the GC and its PC hoping that nothing will go wrong. When the power failure occurred just now, the oven temperature (of the GC) was 250oC. The standard operating procedure to switch off the GC is when the oven temperature is below 40oC. Sudden GC shut down is not recommended at all. It is strictly a big NO. Luckily the GC works well and nothing seems to be wrong. I restarted my experiment and completed it 3 hours later.
Power Failure in the Plant
The incident reminded me on the power failure that once in a while also occurred in the physical refinery plant I worked in several years ago. Such unavoidable power cut-off from the Electricity Company will firstly trigger chaos within the control room and the entire plant. The supervisor, shift leader and plant operators have to act fast to close all main valves manually from various sections. The flow, temperature and pressure from numerous unit operation equipment such as Niagara filter (filter leaves), deodoriser, packed column, heat exchanger need to be controlled until power resumed. The huge 3000 tonnes per day plant can only be minimally controlled via the PLC which was temporarily powered with UPS (uninterupted power supply) - which provided a few minutes power back up.
Secondly, the power cut off will result in substantial lost and I have to assess and make report about it. Even a milisecond power failure will result in vacuum drop in the plant in result to oil rejection (due to quality off-spec). That also will cost massive lost to the company.
What can we do?
As for my case, in the lab... nothing much can be done. I rest my faith to the God. It's good to install UPS for the GC. If UPS is the answer, then we must have 4 UPS unit in the lab as there are all together 3 GC's and 1 GCMS. However, having UPS alone will not entirely protect this expansive machines. For me, the power company (electricity supplier) must be responsible in providing smooth and reliable power for us (the customers). They should pay all the damage and losses that hit us. Maybe this does not sound like an engineer's solution...
Other option?
A more interesting option is to create and manage our own power system...but can we do it with our resources? I'm referring to solar, wind and frequency (Tesla) energy. I would love to develop one of this power sources AFTER I complete my study. I'll try and do it at my home first... :)
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Have you downloaded my free "Choosing Alternative Fuel" Ebook? If not, then please download it here. It's Free and on top of getting the free ebook, you'll get eCourse on Alternative Fuel. It's a good and easy way to add more valuable information to yourself. Image #1 credited to: http://www.wkow.com/Global/story.asp?S=14691294&clienttype=printable Image #2 credited to: http://www.msnbc.msn.com/id/42761336/ns/us_news-life/t/refinery-warnings-way-life-texas-city/
I'm now in my 4th semester of my Ph.D studies. I will be lying if I say that doing Ph.D is easy. It's not as easy as that. I told my wife few months ago that preparing the project report for my Institution Engineers Malaysia (IEM) interview (to be a professional engineer) was tougher than doing my Ph.D. I'm wrong!!! Maybe that time, I was not really focus on my Ph.D. But now, as I'm more focus with my studies, I am well aware that completing this study is not as easy as it seems to be. It is so tough. Ask anybody who successfully completed their Ph.D... Nobody says it is easy.
Suddenly I felt time is very limited. I'm beginning to feel the pressure. I have more or less one year to complete my studies. I need to start working on my experiments. My experimental rig is fine and I believe it will be ok as I already tested it several times. The only concern for me is the quartz reactor that is brittle in nature. I need to keep sufficient stock of it. In addition, I also need to ensure my other equipments and consumables have spare as well. When talking about the experimentation work, the Gas Chromatography (GC) should also be in perfect condition for me and my Iranian colleague (Maryam) to analyze our products. The GC is the basically the heart of the study besides the rig reactor and process. I'm going to start my experimental work tomorrow officially and I hope everything will be fine... (Need to pray a lot!!!) OK ...enough about the experimental work.
Journal Paper... This is another thing hunting my back and consuming a huge chunk of my time. I have a draft prepared and submitted to 2 reputed publishers only to see on both occasions it got rejected for funny reasons (the first one) and out of scope reason (the second one). I admit that I felt miserable being rejected just like that. Well... I need to bounce back and fight to improve my draft paper and then send it again to other journal.
Thermodynamic modeling... Yeah...not only experimental work, I also need to work on the thermodynamic modeling of my catalytic reaction. This is quite interesting but at the same time it is my weakest part. I'm slowly working on this section and I hope I can complete this study in the next 2 months... (also, I need to pray to God a lot on this). I'm receiving some help from Maryam on this. She has been helping me when I got confuse and lost.
There are certainly a lot more to share about my research journey as a Ph.D student. I think I should reserve the rest for future sharing. For the time being, I just need to focus on my study for a while. Wish me luck... :)
Before ending... I would like to thank my other half of her undivided support for me. It is good to have a partner who is also in the same chemical engineering field. She understood what I'm doing and at the same time provided me precious input and ideas.
Also, my other colleague in the lab... All of you are great...haha...especially Emm2020...who has been next door to me in the lab...Let's finish this together!!!
p/s: Sorry if this post is not of any benefit to you guys. I just need to vent off some tense in me.
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I’m Zaki. I used to be a project, process and chemical engineer. Few years ago I successfully became a Chartered Engineer (IChemE) and Professional Engineer (BEM). I'm now employed as a chemical engineering educator/researcher/consultant. Hope you like reading my blog. I welcome any feedback from you. My email: zaki.yz[alias]gmail.com. TQ!
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