Master Chemical Energy Engineering Module Process Control

Otto-von-Guericke-Universität Magdeburg
Fakultät für Verfahrens- und Systemtechnik
Modulhandbuch Chemical and Energy Engineering
Wahlpflichtfächer

Modulhandbuch für den

Masterstudiengang

Chemical and Energy Engineering

- Wahlpflichtveranstaltungen -

Stand: 04.02.11
vorläufig

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Course: Master Course

Module:
Process Control

Objectives
Students should
 learn fundamentals of multivariable process control with special
emphasis on decentralized control
 gain the ability to apply the above mentioned methods for the
control of single and multi unit processes
 gain the ability to apply advanced software (MATLAB) for
computer aided control system design

Contents

1. Introduction
2. Process control fundamentals
 Mathematical models of processes
 Control structures
 Decentralized control and Relative gain analysis
 Tuning of decentralized controllers
 Control implementation issues
3. Case studies
4. Plantwide control
Teaching
Lecture and exercises/tutorials
Prerequisites
Basic knowledge in control theory

Workload:
Lectures and tutorials:
 2 hours/week – lecture
 1 hour/week – exercise/tutorial
Private studies
 Post-processing of lectures, preparation of project work/report and exam

Examination/Credits:
- oral 4 CP and project report
Responsible lecturer: Prof. Kienle with Dr. Sommer as co-worker

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Course:
Master Course Chemical and Energy Engineering
Module: Drying Technology

Objectives:
The students gain fundamental and exemplary deepened knowledge about the state of drying
technology. They learn to understand and calculate heat- and matter transport processes
proceeding the different drying processes. The most important types of dryers from industrial
applications will be explained and calculated exemplary for different drying processes. The aim
of the module is, to impart ready to use knowledge to the listeners about calculation of drying
processes and especially about their construction.

Contents
 The ways of adhesion of the liquid to a commodity, capillary manner, ideal and real
sorption, sorptions isotherms
 Characteristics of humid gases and their use for Nutzung für die convective drying
 Theoretical handling of real dryers: single stage, multi stage, circulating air, inert gas
cycle, heat pump, exhaust vapor compression
 Kinetics of drying, first and second drying section, diffusion on moist surfaces, Stefan-
and Ackermann correction, standardized drying process
 Convecting drying at local and temporal changeable air conditions
 Fluid bed drying with gas and overheated solvent vapor
 Fluidized bed granulation drying and various control options of drying plants with and
without heat recovery
 types, constructive design and calculation possibilities of selected types of dryers, such
as compartment dryers, fluidized bed dryers, conveying air dryers, drum dryers, spray
dryers, conveyor dryers, disk dryers et al.
 Exemplary calculation and design of selected dryers
Teaching: lecture (presentation), examples, script, excursion in a drying plant,
Literature: Krischer / Kröll/Kast: „Wissenschaftliche Grundlagen der Trocknungstechnik“ (tome 1)
„Trockner und Trocknungsverfahren“ (tome 2), „Trocknen und Trockner in der Produktion“ (tome
3), Springer-Verlag 1989,
H. Uhlemann, L. Mörl: „Wirbelschicht-Sprühgranulation“, Springer-Verlag, Berlin-Heidelberg-
New-York 2000
Prerequisites:
Basics of process engineering
Workload: 3 SWS
Lectures: 42 hours
Private: 48 hours
- M 4 CP
Responsible lecturers: Prof. Tsotsas with Jun.-Prof. Metzger as co-worker

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Course:

Module: Electrochemical Process Engineering

Objectives:
The lecture conveys physicochemical and engineering basics of electrochemical process
engineering (EPE). In the first part fundamentals of EPE including electrochemical
thermodynamics and kinetics, transport phenomena, current distribution and electrochemical
reaction engineering will be discussed. In the second part typical applications of electrochemical
technologies like electrolysis processes and electrochemical energy sources will be reviewed.
Finally, electrochemical fundamentals of corrosion, as well as corrosion prevention and control
will be explained. The lectures will be followed by experimental laboratory courses which should
contribute to a better understanding of the theory part.

Contents:
 Introduction (Fundamental laws, Figures of merit, Cell voltage)
 Basics of electrochemistry (Ionic conductivity, Electrochemical thermodynamics, Double
layer, Electrochemical kinetics)
 Mass transport (Diffusion, Migration, Convection)
 Current distribution (Primary, Secondary, Tertiary)
 Electrochemical reaction engineering ( Electrolyte, Electrodes, Separators, Reactors,
Mode of operation)
 Electrolysis (Chlor-alkali electrolysis, Organic electrosynthesis, Electroplating)
 Electrochemical energy sources (Batteries, Supercapacitors) and Corrosion and its
control
Teaching: lectures (2 SWS), tutorials (1 SWS)

Prerequisites
 Basic knowledge in chemistry and physical chemistry
 Mass and heat transport
 Chemical reaction engineering
Work load: 3 SWS
lectures and tutorials: 42 Stunden
private studies: 48 Stunden
Examinations / Credits:
- M 4 CP
Responsible lecturer: Dr.-Ing. Vidaković / Prof. Sundmacher
Literature:
 V. M. Schmidt, Elektrochemische Verfahrenstechnik, Grundlagen, Reaktionstechnik,
Prozessoptimierung, Wiley-VCH GmbH & Co. KGaA, 2003,
ISBN 3-527-29958-0.
 K. Scott, Electrochemical Reaction Engineering, Academic Press Limited, 1991, ISBN 0-
12-633330-0.
 D. Pletcher, F. C. Walsh, Industrial Electrochemistry, 2nd Edition, Blackie Academic &
Professional, Paperback edition, 1993, ISBN 0-7514-0148-X.

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Course:

Module: Measurement of physical particle properties

Objectives:

• Theoretical fundamentals of experimental characterisation techniques for particle
characterisation are to be understood and applied,
• the instrumental realisation, experimental procedures and approaches for data evaluation
are to be understood and applied,
• problem solutions by efficient application of the particle characterisation techniques for
mechanical processes in the particle technology (product design) are to be developed

Contents:

 Introduction, properties of particulate materials, particle size and particle size
distribution, characteristic parameters, particle shape, particle surface and packing,
 Particle size and shape, image analysis, optical microscopy, TEM, SEM, light
scattering, laser diffraction, ultra sonic damping and ESA techniques, instruments,
 Particle density, solid particle density, apparent density, bulk density, gas and powder
pycnometry, instruments, term porosity,
 Specific surface area and porosity, surface structures of solid materials, pore and pore
size distribution, adsorption measurements, data evaluation, BET, BJH, Hg porosimetry,
instruments,
 Electro-kinetic phenomena, fundamentals, electrochemical double layer, surface
potential, electrophoresis, Zeta potential, theories, instruments,
 Particle adhesion, adhesion force measurements, atomic force measurements AFM,
centrifugal techniques, instruments, particle and agglomerate strength, particle breaking,
mechanolumineszenz,
 Characterisation of particle packings, packing states, packing density, fundamentals
of flow behaviour of particulate solids, flow characteristics and parameters, measurement
of flow properties, translation and rotational shear cells, press shear cell,
 Characterisation techniques for moving packings and beds, fundamentals, particle
movement in rotating apparatus, characterisation techniques,

Teaching: lecture

Prerequisites: Mechanical process engineering

Work load: 2 SWS
Lectures: 28 h
Private studies: 32 h
Examinations/Credits:
- M 3 CP
Responsible lecturer: Prof. Tomas with Dr. Hintz as co-worker

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Module: Micro Process Engineering

Objectives:
 Basic understanding of all important physical and chemical phenomena relevant in
microstructures
 Real-life know-how and relevant methods for choice, evaluation and designing of
microstructured process equipment
 Adequate model representations for realistic and convenient design and simulation of
microstructured process equipment

Contents:
- Heat and mass transfer in microstructures
- Safety and economic aspects of microstructured process equipment
- Designing of micro heat exchangers, mixers and reactors
- Role of surface/interfacial forces: Capillary effects and wetting
- Design concepts of microstructured equipment, commercial realisations and suppliers
- Process design and scale-up of microstructured process equipment
- Real life experience: Design rules, Dos & Don’ts
- Limitations of microstructured process equipment

Teaching:
Seminar-style lecture with group work (calculation examples etc.)

Prerequisites
Heat Transfer, Fluid Mechanics, Chemical Reaction Eng.
Also helpful: Process Systems Engineering, Process Dynamics.

Work load: 3 SWS lecture incl. group work
39h lectures and tutorials
10h private studies

Examinations / Credits
Written (90 min.); If less than 20 participants: Oral examinations (30 min.) / 4 CP

Responsible lecturer:
Dr.-Ing. T. Schultz (Evonik Degussa GmbH) with Prof. Dr.-Ing. K. Sundmacher as co-worker

Supplemental literature:
 W. Ehrfeld, V. Hessel, H. Löwe: Microreactors, Wiley-VCH, Weinheim, 2000
 V. Hessel, S. Hardt, H. Löwe: Chemical Micro Process Engineering: Fundamentals,
Modeling and Reactions, Wiley-VCH, Weinheim, 2004
 V. Hessel, S. Hardt, H. Löwe: Chemical Micro Process Engineering: Processing,
Applications and Plants, Wiley-VCH, Weinheim, 2004
 W. Menz, J. Mohr, O. Paul: Microsystem Technology, Wiley-VCH, Weinheim, 2001

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Course:

Module: Modeling with population balances

Objectives:

Participants learn to:
 characterize systems with density functions
 model nucleation, growth and agglomeration
 solve population balances (analytical solutions, momentum approaches, sectional
models)
 apply population balances to real problems

Contents:

The concept of population balances is one approach to describe the properties of disperse
systems. By definition a disperse system is a population of individual particles, which are
embedded in a continuous phase. These particles can have different properties (internal
coordinates) such as size, shape or composition. The concept of population balances allows to
predict the temporal change of the density distribution of the disperse phase. By heat, mass and
momentum transfer between the disperse and the continuous phase and by interaction between
individual particles of the disperse phase the density distribution of the particles will change.
These mechanisms are characterized as population phenomena.
 nucleation,
 growth,
 breakage and
 agglomeration

:
Teaching: lectures and tutorials

Prerequisites:

Work load: 3 SWS
lectures and tutorials: 42 h
private studies: 48 h

- M 4 CP
Responsible lecturer: Jun.-Prof. Peglow

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Course:

Module: Modern organic synthesis

Objectives:

Constitutive to the basic knowledge of the „Chemistry“ module in this module the expertise for
development of strategy for complex synthesis will be procured. On example of chosen synthesis
the principles of total synthesis will be trained.

Contents:

 Short overview reactivity, carbon hybrids, organic chemical basic reactions
 Concept of the acyclic stereoselection on the example of Aldol reactions
 Demonstration of the concept on the example of miscellaneous total synthesis of natural
products
 Basics of metal organic chemistry
 Vinyl silanes
 Allyl silanes

:
Teaching: Lecture

Prerequisites: Module Chemistry

Work load: 2 SWS
lectures: 28 Stunden
private studiens: 32 Stunden
- M 3 CP
Responsible lecturer: Prof. Schinzer

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Course:
Module:
Molecular Modeling
Objectives:

The students acquire theoretical and practical knowledge on the principles and applications of
different modeling approaches for discrete systems of particles, molecules and atoms on
different time and length scales. They will be introduced to Monte Carlo methods, molecular
dynamics and basic quantum mechanical modeling on different relevant practical applications of
chemical engineering interest.

Contents:

 Introduction to concepts and basics of molecular modeling
 Basics of simulation tools for different time and length scales
 Monte Carlo methods
o Introduction
o Equilibrium methods – Metropolis algorithm
o Non-equilibrium methods – Kinetic Monte Carlo
o Application to particle precipitation
 Molecular Dynamics
o Basics and Potentials
o Algorithms: Verlet, Velocity Verlet, Leap-Frog
o Application to diffusion and nucleation
 Quantum Mechanics
o Introduction
o Force fields
o Density function theory
 Recent progress and modern software tools

Teaching:
Lecture and seminar
Prerequisites:
Basic knowledge on physics and chemistry and numerical methods
Workload:
- Lectures and seminar: weekly lecture (90 min),
bi-weekly computer lab seminar (90min)
- Suggested self study time: 48h per semester
Programming home work and oral exam / 4 CP
Responsible lecturer: Dr. A. Voigt

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Course:

Module: Nanoparticle technology

Objectives:

Students get to know main physical and chemical theories on nanoparticle formation and
particle formation processes including important technical products. The lecture includes
modern physical characterisation methods for nanoparticles as well as application
examples for nanoparticles

Contents:

• Introduction into nanotechnology, definition of the term nanotechnology and
nanoparticle, nanoparticles as a disperse system, properties, applications
• Thermodynamics of disperse systems, nucleation theory and particle growth,
homogeneous and heterogeneous nucleation, nucleation rates, model of LaMer and
Dinegar, Ostwald ripening, agglomeration
• Electrochemical properties of nanoparticle, surface structures, electrochemical
double layer, models (Helmholtz, Gouy-Chapman, Stern), electrochemical potential, Zeta
potential
• Stabilisation of disperse systems, sterical and electrostatic stabilisation, DLVO theory,
van-der-Waals attraction, electrostatic repulsion, critical coagulation concentration,
Schulze-Hardy rule, pH and electrolyte concentration
• Coagulation processes, coagulation kinetics, fast and slow coagulation, transport
models, Smoluchowski theory, interaction potential, stability factor, structures
• Precipitation process, basics, precipitation in homogeneous phase, nucleation,
particle growth, reaction processes, particle formation models, apparatuses (CDJP, T
mixer), hydro thermal processes
• Precipitation in nano-compartments, principles, nano compartments, surfactant-water
systems, structures, emulsions (micro, mini and macro), phase behaviour, particle
formation, kinetic models
• Sol-Gel process, Stöber process, titania, reactions, stabilisation, morphology, pH,
electrolyte, RLCA, RLMC, drying, gelation, aging, coating, thin films, ceramics
• Aerosol process, particle formation, gas-particle and particle-particle conversion, flame
hydrolysis, Degussa and chlorine process, soot, spray pyrolysis
• Formation of polymer particles (latex particles), emulsion polymerisation, theory of
Fikentscher and Harkins, perl polymerisation, latex particles
• Nanoparticles und and their application, technical products, silica, titania, soot,
Stöber particles, nanoparticles in medicine and pharmaceutics, functionalised
nanoparticles, diagnostics, carrier systems, magnetic nanoparticles and liquids,
• Characterisation of nanoparticles - particle sizing, TEM, SEM, light scattering, laser
diffraction, theory (Rayleigh, Fraunhofer, Mie), ultra sonic and ESA technique,
Instruments
• Characterisation of nanoparticles - Zeta potential determination, electrokinetic
phenomena, electrophoresis, electro osmosis, streaming and sedimentation potential,
electrophoretical mobility, Zeta potential, theories according to Smoluchowski, Hückel,
Henry, electrophoretical mobility, instruments, PALS techniques

Teaching: lecture, tutorials, laboratory work (nanoparticle synthesis)

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Prerequisites:

Work load 3 SWS
Lectures and tutorials 42 hours
Private studies: 48 hours
- M 4 CP
Responsible lecturer: Prof. Tomas with Dr. Hintz as co-worker

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Course:

Module: Parameter estimation in engineering

Objectives:
In many situations, engineers need to estimate model parameters from experimental data.
However, due to measurement error, the parameters cannot be obtained exactly, but only in
terms of confidence intervals. The aim of the lecture is to provide engineers with mathematically
correct methods for such parameter estimation.
The necessary tools – like matrix analysis, random variables, probabilities and statistics – are
supplied in the lecture. Several aspects of linear regression and non-linear parameter estimation
are treated: hypothesis testing for parameter values; residual analysis for model testing; known
and unknown measurement noise; constant and variable measurement error; sensitivity analysis
and identifiability of parameters; Monte Carlo simulations of experiments to determine errors on
estimates.
The theoretical tools are demonstrated in examples and exercises from heat and mass transfer
as well as chemical engineering. Several computer lab sessions help students to use MATLAB
for solving problems of parameter estimation.

Contents:
 Introduction to random variables and probabilities
 Estimators, confidence intervals and hypothesis testing
 Matrix operations: determinant, inverse, diagonalisation, quadratic form
 Linear parameter estimation: ordinary, weighted and total least squares
 Linear parameter estimation: residual correlation, choice of model, maximum a posteriori
estimation, sequential estimation
 Non-linear parameter estimation: Gauss-Newton iteration, identifiability, Monte Carlo
simulations, propagation of errors
 Parameter estimation for non-analytical problems

Teaching:
Lecture, tutorial (exercises are presented by students), computer lab.

Prerequisites:
Basic knowledge of matrix analysis and probabilities and some experience in MATLAB would be
of advantage, but are not absolutely required.

Workload: 3 SWS
Lectures and tutorials: 42 hours

one exercise must be presented to the class / oral / 4 CP

Responsible lecturer: Jun.-Prof. Metzger

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Course:

Module: Population Dynamics of Chemical and Biological Systems

Objectives:
The students acquire the theoretical principles of population dynamics modelling and its
application to a variation of process systems. Basic physical, chemical and biological
phenomena are introduced and their fundamental relation to important population phenomena
like nucleation, growth, agglomeration and breakage are highlighted and analysed. The
introduction to global process modelling including material balancing and population dynamics
will enable the students to understand , to model and to control technical processes for the
production of disperse products.
Contents:
 Introduction to populations: Fundamental principles and characterisation
 Properties of distributions: Representation, functions, moments
 Fundamentals of population balance equations and numerical solution methods
 Crystallisation: Kinetics of nucleation, dissolutions and growth, model reductions
 Emulsions: Coalescence and breakage kernels, droplet size distribution dynamics
 Biological systems: Modelling virus replication in cells with discrete event methods
 Measurement principles for population properties: photon correlation spectroscopy, laser
back reflection, electron microscopy, dynamic light scattering, fluorescence counters, flow
cytometry
Teaching:
2SW Lecture and 1SWS Seminar for practical applications
Prerequisites:
Principals of process engineering and numerical methods
Work load: 3 SWS
Lectures and tutorials: 42 h
Examinations /Credits:
- M 4 CP
Responsible lecturer: Dr. Voigt / Prof. Sundmacher
Literature:
 Ramkrishna, D., Population Balances: Theory and Application to Particulate Systems in
Engineering, Acad. Press, New York, 2000.
 Mersmann, A., Ed., Crystallization Technology Handbook, 1. Edition, Marcel Dekker,
New York, 1995.
 Takeo, M. Disperse Systems, Wiley-VCH, 1999.
 Alberts B, Bray D, Lewis J. 2002. Molecular biology of the cell. 4th ed. Garland
Publishing, Inc.

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Course:

Module: Process Engineering of Metals and Ceramics

Objectives:

Training of application of simultaneous heat transfer, mass transfer, reaction and combustion in
industrial processes.

Contents:
 Manufacturing process of steel, basic reactions, handling of raw material
 Thermal and chemical treatment of raw materials in shaft kilns and cupola furnaces
(reaction kinetics, heat and mass transfer, fluid dynamics)
 Modeling of lime calcination as example
 Thermal and chemical treatment of materials in rotary kilns
 Manufacturing process of ceramics, shaping, drying, sintering
 Thermal and chemical treatment of shaped material in roller kilns and tunnel kilns
 Casting and shaping processes of metals (steel, copper, aluminium)

Teaching: Lectures with experiments and excursions

Prerequisites: Thermodynamics, Heat and Mass Transfer

Work load: 3 SWS
Private studiens: 48 h
- M 4 CP
Responsible lecturer: Prof. Specht

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Course:

Module: Product quality in the chemical industry

Objectives:

Understanding the
● Requirement profiles for products of the chemical and process industry
● Relation between structure and functionality of complex products
● Opportunities and methods for product design

Contents:

● Fundamentals of product design and product quality in the chemical industry (differences to
mechanical branches of industry, customer orientation, multi-dimensionality and complexity as
opportunities for product design)
● Formulation and properties of granular materials (dustiness, fluidizability, storage, color and
taste, pourability, adhesion and cohesion, bulk density, redispersibility, instantization etc.)
● Detergents (design by composition and structure, molecular fundamentals and forces,
tensides and their properties, competitive aspects of quality, alternative design possibilities,
production procedures)
● Solid catalysts (quality of active centres, function and design of catalyst carriers, catalyst
efficiency, formulation, competitive aspects and solutions in the design of reactors, esp. of fixed
bed reactors, remarks on adsorption processes)
● Drugs (quality of active substances and formulations, release kinetics and retard
characteristics, coatings, microencapsulation, implants, further possibilities of formulation)
● Clean surfaces (the "Lotus Effect", its molecular background and its use, different ways of
technical innovation)
● Short introduction to quality management after ISO in the chemical industry (block lecture and
workshop by Mrs. Dr. Fruehauf, Dow Deutschland GmbH)

Teaching: Lectures / Exercises / Lab exercises / Workshop

Prerequisites

Work load: 3 SWS
Examinations /Credits:
- M 4 CP
Responsible lecturer: Prof. Tsotsas

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Course:

Module: Simulation of Particle Dynamics by Discrete Element Method (DEM)

Objectives:

• Recognition and analysis of problems with respect to particle dynamics (technological
diagnostics),
• Understanding the fundamentals of particle dynamics and simulations, using this new
knowledge for modelling methods as well as model synthesis and to simulate
technological and processing problems (technological therapy and software design),
• Development of problem solutions especially for mechanical processes by effective
simulation algorithms (advanced process design) including improved functional design of
machinery and apparatuses.

Contents

• Introduction, Discrete Element Method, basic ideas, Itasca-software, different program
versions and modules, software and programming levels, basic commands,
• Particle interactions and contact mechanics, 6 mechanical degrees of freedom,
decomposition of contact forces in normal and tangential components, rolling and
torsional moments, contact normal force as free oscillating undamped mass-spring
system, elastic spherical contact by Hertz theory,
• Discrete Element Method, forward calculations in incremental time steps, balances of
forces and moments, equations of movement of every primary particle, contact
interactions and solid bridge bondings, general particle and particle-wall interactions,
• Calculation examples (translation between two particles in contact as „two-ball“ toy
system), starting values, starting geometries, force calculations at begin, calculation of
particle velocities by first numerical integration of force balance, calculation of particle
positions by second numerical integration of force balance, selection of time steps,
incremental scaling of density, mechanical damping: loss (dissipation) of kinetic energy,
viscose damping,
• Exercises of simple calculations examples of powder storage and handling.

Teaching: lecture and exercises

Prerequisites: Mechanical Process Engineering, Mathematics
Work load 2 SWS
Lectures and tutorials 28 h
- M 3 CP
Responsible lecturer: Prof. Tomas

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Course:

Module: Storage and flow of particulate solids

Objectives:

• Problems, technical, economic and ecological conditions of storage and solid bulk
handling are to be understood and analysed (Process diagnostics),
• Fundamentals and processes of storage and solid bulk handling are to be understood
and applied, processes and apparatus are to be design (Process design),
• Problem solution by efficient combination of mechanical processes are to be designed
and developed (processing system design)
• Unity of material properties, micro and macro processes, processing system and product
design are to be understood and used

Contents:
• Task and problems of silo or bunker plant,
• Introduction into mechanics of particulate solids, fundamentals of particle
mechanics, adhesion forces, flow characteristics of particulate solids, equations of axial-
symmetric and plane stress fields, flow criteria, powder test equipment and techniques,
flow parameters of cohesive particulate solids,
• Silo and bunker design for reliable flow, hopper design for core and mass flow,
minimal hopper outlet width and angle, discharge mass flow rate,
• Silo and bunker pressure calculation, shaft pressure, hopper pressure distributions,
wall thickness of concrete and metal sheet
• Design and selection of discharge aids,
• Design of discharge devices and selection of valves,
• Introduction into dosing,
• Introduction into design and selection of periphere equipment

Teaching: lecture, tutorials

Prerequisites: Mechanical process engineering, Mechanics

Work load: 3 SWS
- M 4 CP
Responsible lecturer: Prof. Tomas

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Course:

Module: Transport phenomena in granular, particulate and porous media

Objectives:

Dispersed solids find broad industrial application as raw materials (e.g. coal), products (e.g.
plastic granulates) or auxiliaries (e.g. catalyst pellets). Solids are in this way involved in
numerous important processes, e.g. regenerative heat transfer, adsorption, chromatography,
drying, heterogeneous catalysis.
To the most frequent forms of the dispersed solids belong fixed, agitated and fluidized beds. In
the lecture the transport phenomena, i.e. momentum, heat and mass transfer, in such systems
are discussed. It is shown, how physical fundamentals in combination with mathematical models
and with intelligent laboratory experiments can be used for the design of processes and
products, and for the dimensioning of the appropriate apparatuses.

● Master transport phenomena in granular, particulate and porous media
● Learn to design respective processes and products
● Learn to combine mathematical modelling with lab experiments

-
Contents:

● Transport phenomena between single particles and a fluid
● Fixed beds: Porosity, distribution of velocity, fluid-solid transport phenomena
Influence of flow maldistribution and axial dispersion on heat and mass transfer
Fluidized beds: Structure, expansion, fluid-solid transport phenomena
● Mechanisms of heat transfer through gas-filled gaps
● Thermal conductivity of fixed beds without flow
Axial and lateral heat and mass transfer in fixed beds with fluid flow
● Heat transfer from heating surfaces to static or agitated bulk materials
● Contact drying in vacuum and in presence of inert gas
● Heat transfer between fluidized beds and immersed heating elements

Teaching: Lectures / Exercises

Prerequisites:

Work load: 3 SWS
- M 4 CP
Responsible lecturer: Prof. Tsotsas

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Course:

Module: Technical Crystallization

Objectives

Crystallization is a separation method which belongs to the thermal separation processes. Goal
of crystallization is the production of a pure solid crystalline phase which is usually further utilized
as intermediate or end product. Typical tasks for crystallization are separation of mixtures,
purification of solutions, recovery of solvents etc. Single crystal as well as mass crystallization
methods are nowadays well established.
In order to gain deeper insights into this old but up to now not completely understood process,
knowledge from several disciplines (thermodynamics, chemistry, physics, reaction engineering,
thermal and mechanical engineering, fluid dynamics, crystallography, mathematics) is
indispensable. Therefore, crystallization is a prime example for an interdisciplinary research field.
Based on the fundamentals for crystallization selected innovative examples from research and
industry will be presented and discussed during this course.

Contents

1. Introduction
 Short introduction of aspects presented within this lecture
 System characteristics (solubility, driving force, metastable zone width MZW)
 Types of crystallization processes (solution crystallization, evaporative crystallization,
melt crystallization)
 Precipitation
2. Physical-Chemical Foundations
 Thermodynamical aspects (solubilities, phase equilibria, influence of temperature, pH
value, impurities etc.)
 Kinetic aspects (metastable zone width MZW; crystal growth, crystal dissolution;
primary & secondary nucleation; agglomeration; attrition; ripening processes)
3. Selected Measuring Techniques
 Characterization of the liquid phase (density, viscometry, refractometry, ultra sonic,
polarimetry etc.)
 Charakterization of the solid phase (microscopy, fibre sensors, laser diffractometry,
FBRM etc.)
4. Crystallographic Fundamentals
 Crystal habitus, morphology (Miller index, crystal systems), polymorphism
5. Particle Size Distribution
 Crystal size distribution (types of distribution, moments of distributions)
 Particle characterization (sedimentation, microscopy, optical methods, laser diffraction,
focused beam reflectance measurement FBRM)
6. Mathematical Description of Crystallization Processes

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 Modeling & simulation of crystallization processes (batch- & continuous crystallization)
 Optimization of crystallization processes
7. Examples from Industry & Research
 Industrial crystallization (application fields, types of crystallizers etc.)
 Crystallization as separation method for the manufacture of pure enantiomers

Teaching: Lectures and tutorials

Prerequisites: Thermodynamics, reaction engineering, chemistry, mathematical background

Work load: 3 SWS
- M 4 CP
Responsible lecturer: Dr. Elsner
Literature:

- Atkins, P.W. (2004): Physikalische Chemie, 3. Auflage, Wiley-VCH Weinheim
- Gmehling, J.; Brehm, A. (1996): Grundoperationen. Lehrbuch der Technischen
Chemie, Band 2, Georg Thieme Verlag Stuttgart, New York
- Mullin, J.W. (1997): Crystallization, 3rd edition, Butterworth-Heinemann Oxford
- Mersmann, A. (2001): Crystallization technology handbook, 2nd edition, Marcel Dekker
Inc. New York
- Vauck, W.R.A., Müller, H.A. (1994): Grundoperationen chemischer Verfahrenstechnik,
10. Aufl., Dt. Verlag für Grundstoffindustrie Leipzig
- Hofmann, G. (2004): Kristallisation in der industriellen Praxis, Wiley-VCH Weinheim

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Course:
Module:
Biofuels – Sustainable Production and Utilisation

Objectives: The lecture will give an overview of the conversion of biomass to various fuels. The
biomass resources, the production processes as well as their energetic, economical and
ecological aspects will be declared. The principles of the sustainability and life cycle assessment
(well-to-wheel) for the production and utilization of biofuels will be presented.

Contents

1. Renewable biomass sources in comparison to fossil sources

2. Biomass feedstock and intermediates

3. Biofuels (Ethanol, FAME, FT-Fuels, biogas, methanol, hydrogen)
 Properties, utilization, comparison to fossil fuels

4. Production Processes
 Ethanol production routes (conventional – lignocellulosic)
 Biodiesel: Transesterification and hydrogenation
 Thermochemical conversion: Biomass Gasification and Pyrolysis
 Fischer-Tropsch process for biomass-to-Liquid (BTL) conversion
 Algae utilisation for biofuel production (hydrogen and liquid fuel)
 Production costs and relation to GHG Emissions

5. Sustainability of biofuel production and utilisation

 Principles of LCA and case studies for biofuel production

Teaching
Lectures
Private studies: literature research with the university library on-line database system and a
preparation of a literature survey for actual subject in the field.

Prerequisites
Basic courses of chemistry and chemical engineering (Bachelor level)

Workload:
Lectures: 2 SWS
Private studies: 1 SWS (literature survey)
- oral examination / 4 CP
Responsible lecturer: Dr. Techn. L. Rihko-Struckmann, MPI Magdeburg
Tel: 0391-6110 318 , email: rihko@mpi-magdeburg.mpg.de

Wahlpflichtfächer

Course:

Module: Challenge Climate Change

Objectives:

The students should be able to understand the problems and scenarios for global warming and
control of CO2 emissions

Contents:
 Mechanism of global warming: sun radiation, air circulation in atmosphere, rain, flow of
oceans, climate
 Modelling of heat transfer, radiation between earth and clouds, influence of radiative
gases, calculation of earth temperature in dependence on CO2-concentration, adsorption
of CO2 in oceans
 Developing of world energy consumption, scenarios of global warming
 Energy consumption in private households, traffic, industry, trade
 Concepts of lowering CO2-emissions, possibility to improve efficiency, concepts of CO2
capture and storage
 Ecological balances, energy for supply and production of fuels and energy, problems of
allocation, impact of emissions, examples for waste water pipes, comparison of energy
consumption for the production of different materials

Teaching: Lectures with Seminars

Prerequisites: Heat and Mass Transfer, Thermodynamics

Work load: 2 SWS
Private studies:
- M 3 CP

Wahlpflichtfächer


Module: Computational Fluid Dynamics

Objectives
Students participating in this course will get both a solid theoretical knowledge of Computational
Fluid Dynamics (CFD) as well as a practical experience of problem-solving on the computer.
Best-practice guidelines for CFD are discussed extensively. CFD-code properties and structure
are described and the students first realize the own, simple CFD-code, before considering
different existing industrial codes with advantages and drawbacks. At the end of the module, the
students are able to use CFD in an autonomous manner for solving a realistic test-case,
including a critical check of the obtained solution.
Contents
1. Introduction and organization. Historical development of CFD. Importance of CFD. Main
methods (finite-differences, -volumes, -elements) for discretization.
2. Vector- and parallel computing. Introduction to Linux, main instructions, account
structuration, FTP transfer.
3. How to use supercomputers, optimal computing loop, validation procedure, Best Practice
Guidelines. Detailed introduction to Matlab, presentation and practical use of all main
instructions.
4. Linear systems of equations. Iterative solution methods. Examples and applications.
Tridiagonal systems. ADI methods. Realization of a Matlab-Script for the solution of a
simple flow in a cavity (Poisson equation), with Dirichlet-Neumann boundary conditions.
5. Practical solution of unsteady problems. Explicit and implicit methods. Stability
considerations. CFL and Fourier criteria. Choice of convergence criteria and tests. Grid
independency. Impact on the solution.
6. Introduction to finite elements on the basis of Femlab. Introduction to Femlab and
practical use based on a simple example.
7. Carrying out CFD: CAD, grid generation and solution. Importance of gridding. Best
Practice (ERCOFTAC). Introduction to Gambit, production of CAD-data and grids. Grid
quality. Production of simple and complex (3D burner) grids.
8. Physical models available in Fluent. Importance of these models for obtaining a good
solution. Introduction to Fluent. Practical solution using Fluent. Influence of grid and
convergence criteria. First- and second-order discretization. Grid-dependency.
9. Properties and computation of turbulent flows. Turbulence modeling, k- models,
Reynolds-Stress-models. Research methods (LES, DNS). Use of Fluent to compute a
turbulent flow behind a backward-facing step, using best practice instructions.
Comparison with experiments. Limits of CFD.
10. Non-newtonian flows, importance and computation. Use of Fluent to compute a problem
involving a non-newtonian flow (medical application), using best practice guidelines.
Analysis of results. Limits of CFD.
11. Multi-phase flows, importance and computation. Lagrangian and Eulerian approaches.
Modeling multi-phase flows. Use of Fluent to compute expansion of solid particles in an
industrial furnace, using best practice guidelines. Comparison with experiments. Limits of
CFD.
12.-14. Summary of the lectures. Short theoretical questionnaire. Dispatching subjects for the
final CFD-project, begin of work under supervision. Students work on their project during the last
weeks, using also free time. In the second half of the last lecture, oral presentations by the
students of the results they have obtained for their project, with intensive questions concerning
methods and results.
Teaching

Wahlpflichtfächer
Lecture and hands-on on the computer
Prerequisites
Fluid Dynamics
Workload: 3 SWS
Written and oral 4 CP
Responsible lecturer: Dr. G. Janiga with Prof. D. Thévenin as co-worker

Wahlpflichtfächer

Course:
Module:
Fuel Cell Technology
Objectives:
The lecture gives an introduction to the basic principle, technical issues and future developments
of fuel cells. The theoretical part covers aspects on electrochemical thermodynamics,
electrochemical reaction kinetics, mass transport and modeling of fuel cells. The technical part
covers the different types of fuel cells and their current applications, fuel processing and
experimental methods.
Contents:
- Introduction to fuel cells, types of fuel cells and historical aspects
- Electrochemistry basics; double layer phenomena, electrochemical equilibrium,
reaction kinetics, efficiencies
- Mass and energy transport in porous structures
- Modeling of fuel cells
- Experimental methods; equipment and methods, laboratory
- Fuel processing; fuels, handling and production of hydrogen
- Fuel cell systems
Teaching:
Lecture and Tutorial
Prerequisites:
Basic knowledge on thermodynamics, reaction engineering and mass transport is advantageous.
Workload:
- Lectures and tutorials: Full-time block seminar (5 days, Monday-Friday)
- Private studies: 1h per lecture day
Oral exam/4 CP
Responsible lecturer: Dr. R. Hanke-Rauschenbach with Prof. K. Sundmacher as co-worker

Course: Wahlpflichtfächer
Module:
Functional materials for energy storage
Objectives:
The course starts with a short analysis of the imperative of energy storage in general followed by
a classification of storage methods related to the different kinds of energy (thermal, electrical,
chemical). The main storage technologies are described and the materials requirements are
analyzed.
Special focus lies on modern trends in research and application.

Content:
1. Thermal energy
Temperature ranges of energy storage and temperature lift between heat source and
demand,
sensible, latent, adsorption and absorption heat; basics,
differences between short term, long term and seasonal storage,
materials: solid systems, liquid systems
selected applications

2. Electrical energy
Accumulators and batteries: overview, kinds and application fields
gravimetric and volumetric storage density
standard potential, dependence on system temperature and concentration of the reactants
Nernst equation of particular Systems
loading-/deloading kinetics; thermal stress; dimensioning
working systems
super caps: working principle

3. Chemical energy hydrogen, production by electrolysis, storage
Adam / Eva-process

4. Compressed air storage locations, potential, work principles

5. Fly wheels fast and slow, potential, work principles

6. Others e.g. pump storage plant

Teaching:
Lecture
Tutorial
Prerequisites:
None
Workload:
Lecture and tutorials: 3 SWS, (2 lecture, 1 tutorial)
Regular Study: 42 h
Private Study: 78 h
Written 90 min, 4 CP
Responsible lecturer: Prof. Dr. F. Scheffler

Wahlpflichtfächer


Module: Modelling and analysis of energy processes

Objectives
Students learn to use modelling and simulation as tools to get more insight into energy
systems. In a first step, the physicochemical fundamentals of various renewable and
conventional power plants are discussed; subsequently the single process steps are
discussed in detail. Lectures are accompanied by modelling and simulation exercises to
the various topics. In this way, students learn to combine the knowledge on simulation
and the various processes to model and simulate new processes on their own.

Contents

 Energy processes

 Mass and energy balances in energy processes

 Reaction engineering of energy processes

 Heat and mass transfer

 Compression/expansion

 Analysis of energy systems
Teaching
Lecture, 2 SWS
Exercises, 1 SWS

Prerequisites
Fundamentals in programming, thermodynamics, physics and chemistry

Workload:
-Written or project work / 4 CP
Responsible lecturer: Jun.-Prof. Ulrike Krewer

Wahlpflichtfächer

Course:
Module: Modelling and simulation of energy generation systems

Objectives:
Acquisition of the ability to develop and apply methods of simulation for technical systems in
energy generation, interconnected power-grids, and environmental loads
Content:

 Resources, interconnected power grid and environmental protection
 Oil field capacities according to Hubbert
 Short description of technical equipment for converting primary energy into electricity:
o Steam cycle
o Gas turbine cycle,
o Gas and steam turbine cycle
o Water energy
o Nuclear energy
o Solar energy
o Solar thermal power plants
o Photovoltaic energy conversion
o Wind energy
o Biomass
o Fuel cells

 Stochastic modelling of an interconnected grid of three wind turbines
 Thermoshock in a feedwater line
 Water hammer
 Modelling of a coal-fired plant
 Modelling of a gas and steam turbine plant
 Modelling of solar heating and warm water supply
 Availability of a coal-fired plant
 Cost optimal composition of an interconnected power-grid using dynamic programming
 Risik comparison and determination of minimal risk for an interconnected power-grid
(Lagrange multiplyer)
 Energy comsumption of a car
 Modelling of a self-sustained electricity supply based on renewable energies
Numerous models with analytical solutions or numerical solutions using FORTRAN programs
are presented

Teaching approach: Lecture with an overwhelming part of problem presentation

Pre-requisites: Ordinary and partial differential eqiuations, stochastics, thermo and fluid
dynamics
Work load: 2 SWS
Präsenzzeit: 28
Selbststudium:14
oral 3 CP
Responsible lecturer: Prof. Hauptmanns

Wahlpflichtfächer

Course:

Module: Portable und autarke Energiesysteme

Objectives
Students get an insight into the technology for portable and autonomous energy systems,
starting from basic fundamentals and ending at technical systems and their operation. Besides
widely established technologies such as batteries, the lecture covers also fuel cells, supercaps
and energy harvesting.

Contents

 Introduction and definitions

 Electrochemistry

 Batteries

 Supercaps

 Fuel cells

 Energy harvesting
Teaching
Lecture, 2 SWS

Prerequisites
Fundamentals in physics and chemistry

Workload:
:Private studies: 56 h
-Oral 3 CP
Responsible lecturer: Jun.-Prof. Ulrike Krewer

Wahlpflichtfächer

Clean up of Contaminated sites

Course: Master Course Chemical and Energy Engineering

Module: Environmental air cleaning
Objectives

 Recognize and learn to analyze the framework of environmental engineering as
well as the sources and consequences of air pollution
 Understand the principles of mechanical, thermal, chemical and biological
processes of exhaust gas treatment, learn to design such processes and the
respective equipment
 Learn to develop solutions for the prevention of air pollution by efficient
combination of mechanical, thermal, chemical and biological processes

Contents

1. Terms of environmental engineering, legal and economic frame
2. Types, sources, amount and impact of pollutants in exhaust gases
3. Typical separation processes and process combinations for the removal of
pollutants from gases
4. Principles of dust removal, assessment of process efficiency and gas purity,
process and equipment examples: inertial separators, wet separators, particle
and dust filters, electrical separators
5. Removal of gaseous pollutants by condensation, absorption, reactive absorption
6. Removal of gaseous pollutants by adsorption, membranes, biological processes
7. Thermal and catalytic post-combustion

Teaching
Lecture
Tutorial

Prerequisites

Workload:
-Written / 4 CP
Responsible lecturer: Prof. Dr.-Ing. E. Tsotsas with Dr. rer. nat. W. Hintz as co-worker

Wahlpflichtfächer

Course:

Module: Environmental Biotechnology

Objectives:

The students achieve a deeper understanding in microbiological fundamentals. They are
able to characterize the industrial processes of the biological waste gas and biogenic
waste treatment and the corresponding reactors and plants. They know the
fundamentals of the reactor and plant design. They realise the potential of
biotechnological processes for more sustainable industrial processes.

Contents:
 Biological Fundamentals (structure and function of cells, energy metabolism,
turnover/degradation of environmental pollutants)
 Biological Waste Gas Treatment (Biofilters, Bioscrubbers, Trickle Bed Reactors)
 Biological Treatment of Wastes (Composting, Anaerobic Digestion)
 Bioremediation of Soil and Groundwater
 Prospects of Biotechnological Processes – Benefits for the Environment

:
Teaching: Lectures/Presentation, script, company visit

Prerequisites:

Work load: 2 SWS
- Oral 3 CP
Responsible lecturer: Dr. Haida /Dr. Grammel

Wahlpflichtfächer

Course:

Module: Recycling and Mechanical Waste Treatment

Objectives (competences):

• Data acquisition and analysis of sources of solid waste materials, like municipal solid
waste (MSW), building rubble, metal and electronic scraps, plastics waste, including
analysis of economic and technological problems of environmental engineering and
recycling technologies under abidance of legal frameworks
• Understanding and proper treatment of statistically distributed material properties of solid
waste materials and minerals (analysis) to improve recycling product quality (recycling
product design)
• Learning of thorough problem analysis (diagnose) of waste material and mineral
processing and conversions to develop appropriate problem solutions (process design)
• Development and consolidation of creative skills in design and evaluation of complex
recycling processes (process and plant design)

Content:

• Fundamentals of mineral processing and recycling technology, principles of
environmental policy and legal frameworks, complex material circuits and sustainable
technologies
• Physical basics in characterisation of solid waste materials, waste accumulation and
material properties, sampling, fundamentals of particle interactions and transport,
• Liberation of valuables by comminution, stressing conditions, comminution machines
for waste with ductile material behaviour, shear crusher and shredders,
• Classification of waste, fundamentals, processes and classifiers,
• Sorting of waste, fundamentals, microprocesses, processes and separation machines
(density, magnetic, electrostatic separators, flotation, automatic sorting),
• Design of recycling processes and plants, post-consumer waste, building rubble,
metal and electronic scraps, plastics and industrial waste for reuse

Teaching:
Lectures, tutorials with oral presentations and practical tutorials (aerosorting, flotation)

Prerequisites: Mechanical Process Engineering

Workload:
Lectures and tutorials: 42 h, private studies: 48 h

- oral examination
- 4 CP

Responsible lecturer: Prof. Dr.-Ing. habil. Jürgen Tomas

Wahlpflichtfächer

Control of Industrial Toxic Metal Emissions

Course:

Module: Thermal Waste Treatment/Air Pollution Control

Objectives:

The students should be able to use residues as fuel in industrial processes, to incinerate waste
and to apply the techniques to minimize the air pollution.

Contents:
 Characterization and composition of residues and waste
 Classifying and separation of residues and waste
 Thermal decomposition of organic materials, problems and specialities in combustion of
residues, halogens, condensates, corrosion
 Firings (swirl combustion chambers, stoker firings, rotary kilns, blast furnaces, tunnel
kilns), examples for usage in cement and in brick production
 CO2 Emissions, potentials, concepts, capture and storage
 Mechanism of NO emissions (thermal, prompt, fuel NO), methods of reduction (lowering
of temperature, flue gas recirculation, staged combustion)
 Desulfurization (hot, cold, wet methods), soot, hydrocarbons

Teaching: Lectures with examples and excursions

Prerequisites: Combustion Engineering, Verbrennungstechnik

Work load: 2 SWS
- Oral 3 CP

Wahlpflichtfächer

Course:

Module: Waste water treatment

Objectives:

The students are able to characterize the state of the art in waste water treatment (focused on
municipal waste water) and sewage sludge treatment, utilization or disposal corresponding to the
European and German ecolaws. They have basic knowledge of the design of the technical
equipment.

Contents:

 Wastewater: Composition, Characterization
 Mechanical Treatment (screens, grit chambers, sedimentation tanks)
 Biological Treatment
Activated sludge, biofilms, aerobic/anaerobic conversion of organics,
nitrification/denitrification, phosphorus removal
Activated Sludge Plants, Biofilm Systems
 Wastewater Lagoons, Constructed Wetlands
 Chemical and Physical processes, Membranes
 Reactors for anaerobic treatment
 Sludge Treatment: Typical process sequences for utilization or disposal

Teaching: Lecture, Calculation examples, Company visit

Prerequisites:
Process engineering fundamentals
Work load: 2 SWS
- Oral 3 CP
Responsible lecturer: Dr. Haida

Wahlpflichtfächer
Pollution Prevention – Principles and Technologies

Course:

Module: Engineering Risks-Consequences of accidents in industries

Objectives:

Ability to quantitatively assess the consequences of accidents in process plants.

Content:

 Concept of risk
 leak formation and frequency determination
 discharge from tanks and pipes of liquids, gases and two-phase
 airborne and heavier-than-air atmospheric dispersion
 jets
 tank rupture
 fires, sources of ignition
 self heating
 explosions
 BLEVE
 toxic releases
 effects of heat, pressure and toxicity on man
 damage from missiles
 modelling of evacuation
 risk assessment for a pipeline
:
Teaching: Class lectures and tutorial exercises

Pre-requisites: thermo and fluid dynamics

Work load: 3 SWS
Written 4 CP
Responsible lecturer: Prof. Hauptmanns

Wahlpflichtfächer

Course:

Module: Modelling and simulation in industrial safety I + II

Objectives:

Participants acquire the ability to formulate models in plant safety and to develop the
corresponding analytical or numerical models to solve them. In addition, they learn to use
some of the commercial programs in the field.

Contents:

 Introduction to FORTRAN and VBA
 Discharge of hazardous materials
 Fault tree analysis using Monte Carlo
 Commercial programs for analyzing accident consequences
 Uncertainties in engineering calculations
 Entrainment of a tree trunk by a river
 Determination of the time required for dumping the contents of a reactor
 Self-heating
 Dynamic simulation of a reactor for producing trichlorophenol (including cooling failure)
 Catalytic conversion of heptanes to toluene
 Incipient fault detection using neural networks.
 Stability of non-linear systems
 Determination of boundary conditions for emergency trips
 Non-stationary and stationary calculation of a heat exchanger
:
Teaching: Lecture and integrated tutorial

Pre-requisites: ordinary and partial differential equations, ordinary non-linear differential
equations

Work load: 2 SWS + 1SWS
Written 4 CP
Responsible lecturers: Prof. Hauptmanns with Dipl.-Inf. Bernhardt and Dr.-Ing. Gabel as co-
worker

Wahlpflichtfächer

Course:

Module: Safety aspects of chemical reactions

Objectives

Chemical reactions might cause hazards if they proceed without control. A runaway reaction may
occur which ends in a blow-off of a reactor top and an emission of reactants and products,
possibly followed by a gas explosion. Important is a thorough risk analysis if exothermally
reacting chemicals are involved. Exothermic reactions can be quantified using different caloric
and kinetic properties.

To evaluate how safe a chemical reaction can be performed in a certain process or environment
the following two areas will be discussed:

 analysis of underlying chemistry
 analysis of technical implementation and process conditions
 determination of relevant physical & chemical properties

Contents

 General aspects related to chemical reactions
 Causes for hazardous situations, examples of incidents – safety analysis
 Basics of chemical reaction engineering
 Analysis of a continuous stirred tank reactor
 Stability and dynamics
 Relevant data and experimental methods, eg. Thermogravimetry and DSC
 Determination of save operation mode

Teaching: Lecture / Tutorials

Prerequisites: Chemistry

Work load: 1 SWS
written 1 CP
Responsible lecturers: Prof. Seidel-Morgenstern with Dr. Hamel as co-worker
Literature:

-Levenspiel, Chemical Reaction Engineering, John Wiley & Sons, 1972
-Steinbach, Safety assessment of chemical process, VCH, Weinheim, 1999
-Westerterp, van Swaaij, Beenackers, Chemical reactor design and operations, Wiley, 1984

Master Chemical Energy Engineering Module Process Control

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