Bioethanol Production Plant 2023

Developing an advanced bioethanol plant model of superior quality, designed to meet contemporary global standards for achieving net-zero emissions, sustainability, and profitability. Given the collaborative nature of this cross-functional group project, a close and effective collaboration with team members was essential to optimise the project and ensure its overall success..

Key Responsibilities:

• Demonstrate strong leadership by monitoring and coordinating project responsibilities to ensure timely completion.

• Strive to attain a financially feasible system.

• Conduct HAZOP & HAZID analysis to ensure the safety and security of the system.

• Strive for carbon-neutral status by reducing our environmental impact and eventually reaching a net-zero carbon footprint.

Key Achievements:

• Present a successful bioethanol system to industry leaders eg. (Vivergo fuels, Shell, BP)

• Developed comprehensive BFD, PFD, P&ID and mechanical drawing documents for various bioethanol production processes. eg. (Hydrolysis reactor, Distillation column, Centrifuge)

• Achieved a bioethanol production yield of 84 million gallons per year, translating to an annual net profit of £24,000,000.

Lead a collaborative project to develop a hydrogen production plant in the North Sea. Various pathways for hydrogen generation procedures were investigated to ensure that the plant is both economically viable and environmentally friendly. Natural gas reformation to produce hydrogen was compared to a green hydrogen process method. The economic, social, and environmental repercussions of hydrogen produced using conventional and green technologies/routes were investigated.

Key Responsibilities:

• Strive to attain a payback time of less than 5 years for the project.

• Conduct financial planning for the start-up and operational costing for the plant while doing an economic analysis.

• Utilise Aspen Plus software to design the hydrogen production plant process intricately.

• Evaluate sustainability considerations by conducting a comprehensive life cycle assessment through CCaLC software.

Key Achievements:

• Developed comprehensive BFD, PFD, and P&D documents for various hydrogen production processes.

• Successfully achieved a remarkable 4-year payback time for the green hydrogen production plant.

• Analysed life cycle assessment data, affirming that green hydrogen production stands as an environmentally sustainable and attractive prospect for potential investors.

Immersed myself in a dynamic laboratory environment for an extensive 7-week period, where my focus centered on not only gathering data but conducting a comprehensive analysis of chemical engineering equipment and processes. The overarching goal was to pinpoint areas ripe for optimisation within the equipment, while also diligently identifying and mitigating any potential hazards that might be present. This hands-on experience served as a pivotal exploration into enhancing efficiency and ensuring safety within the field of chemical engineering.

The seven pieces of equipment addressed are as follows: distillation column, heat exchanger, adsorption column, absorption column, fluidised bed and a P&ID rig.

Key Responsibilities:

• Follow established safety regulations and protocols while working with harmful substances and machinery. 

• Participating in laboratory meetings, training, and continuing education opportunities to stay updated on relevant techniques and technologies.

•Documenting experimental procedures, results, and observations accurately and thoroughly.

•Analyzing and interpreting experimental data.

Key Achievements:

• Developing new experimental protocols or optimizing existing ones to improve efficiency or results.

• Successfully completing and documenting complex experiments with precision and accuracy.

The laboratory reports and analyses can be viewed on the links below.

1. Fluidised Laboratory

2. P&ID rig

3. Adsorption Reactor 

4. Absorption Reactor 

5. Distillation Column 

6. CSTR & PFR 

7. Heat Exchanger 

I created and engineered a robot using Autodesk 360, employing its software to craft a sophisticated 3D model. Subsequently, I utilised MATLAB coding to program the robot, enabling it to autonomously navigate towards a predefined destination and come to a halt upon reaching the endpoint.

Key Responsibilities:

• Adhering to competition rules, regulations, and safety standards throughout the design and building process. 

• Collaborating effectively with team members to delegate tasks, manage deadlines, and ensure project success.

• Employ AutoCAD to design a compact vehicle, leveraging diverse software development tools like Python and Matlab to facilitate its motion.

Key Achievements:

• Submitted a sophisticated and robust robot to freely move without human assistance to the iMechE Challenge.

• Presenting the final vehicle design and performance data to judges and peers during competition events.

• Receiving recognition for outstanding teamwork, collaboration, and leadership within the team.

 My first advanced project demonstrated my ability to design a high-quality 4-cylinder engine with AutoCAD. This complex project included the meticulous design of critical components such as the piston, piston rings, piston connecting rod, crankshaft, camshaft, and intake valve. This immersive experience not only gave me a thorough understanding of mechanical engineering principles, concepts, and methodologies, but also allowed me to delve into the complexities of the manufacturing process. My extensive research included a thorough examination of manufacturing techniques, weighing the benefits and drawbacks of methods such as die casting and sand casting. This project not only sharpened my technical skills, but also increased my appreciation for the intersection of creativity and precision in engineering design.

Key Responsibilities:

• Demonstrate exceptional time management skills to ensure timely completion of the project while effectively balancing other academic responsibilities.

• Creating detailed and accurate 2D and 3D models of engine components using AutoCAD software. 

• Ensuring that the engine design meets specified requirements, including performance, size, and efficiency targets.

• Performing simulations and analysis to evaluate the structural integrity, thermal performance, and fluid dynamics of the engine design.

Key Achievements:

• Designed and engineered an advanced engine as a pivotal project within my engineering degree, culminating in the attainment of a Level 3 Extended Certificate in Engineering.

• Developing an innovative engine design that meets or exceeds project requirements and objectives.

• Demonstrating strong problem-solving skills by effectively addressing challenges and constraints during the design process.