chemical engineering expertise in academe and as sought by industry session #97 (plenary) monday...

Chemical Engineering Expertise in Academe and as Sought by Industry

Session #97 (Plenary) Monday November 4 11 am-12:30 pm

Grand Ballroom A (Hilton)

Chair: John C. Chen (Lehigh University)Co-chair: James C. Hill (Iowa State University)

Sponsored by: AIChE Council of Fellows AIChE Keynotes & Plenaries AIChE Education Division Council for Chemical Research

Introduction

This plenary session seeks to

(1) Examine the evolving distribution of faculty interests and strengths in US ChE departments

(2) Highlight the chemical engineering expertise and talents sought by industry.

Presenter:Dr. James C. HillUniversity ProfessorIowa State UniversityPast Director, AIChE

2

Introduction to the session

● Conceived by John Chen for the AIChE Fellows Council

● Industry leaders were concerned about apparent shift in ChE faculty expertise

● Are needs of industry being met now & in the future?


Basic idea for this session:●Survey ChE depts to determine degree of shift (or broadening?) of faculty expertise●Survey traditional & non-traditional industry regarding ChE needs & faculty expertise


What we don’t have time for today:

●Determine the driving forces for such shifts in faculty expertise

●Determine if there are significant changes in ChE curricula supporting such shifts

Participants

Dr. James C. Hill, University Professor, Iowa State University, Past Director AIChE, member AIChE Council of Fellows

Dr. John C. Chen, CR Anderson Professor and Dean of Engineering, Emeritus, Lehigh University, Past President AIChE, member AIChE Council of Fellows

Dr. Rui Vogt Alves da Cruz, Associate Director of Research and Development, Dow Chemical Company

Dr. Ashok Krishna, Vice President of Technology, Downstream & Chemicals , Chevron Corporation

Dr. Steven Poehlein, Principal, Elixia Pharma Consulting, LLC

Dr. Jennifer S. Curtis, Distinguished Professor and Associate Dean, University of Florida, Past Director AIChE, member Governing Board CCR

Thanks to Kristine Chin (AIChE) for help in arranging the session

Program of the session:

Introduction: James C. Hill (Iowa State University)

(97a) Evolving Distribution of Faculty Strengths in Chemical Engineering Departments; John C. Chen (Lehigh University)

(97b) Chemical Engineering Skills for the Global Chemical Industry;Rui Cruz

(97c) Petroleum Industry's Need for Chemical Engineering Talent;Ashok Krishna

(97d) Chemical Engineering Skills Sought by Pharmaceutical Industry;Steve Poehlein

Discussion: Moderator -- Jennifer S. Curtis (University of Florida)

Evolving Distribution OfFaculty Strengths In

US Chemical Engineering Departments

Dr. John C. ChenC. R. Anderson Professor and Dean of Engineering, Emeritus

Lehigh UniversityPast President, AIChE

Dr. Chen has professional experience in the process industry, national laboratory and academia. His research on multiphase transport phenomena has been accorded awards by AIChE, ASME, Humboldt Foundation, Max Plank Institute, Association of Engineers Australia, and French Society of Chemical Engineers. He has served as Director on the Boards of the Chemical Council for Research, the AIChE, the Engineering Conferences International, and the Chemical Heritage Foundation. He served as AIChE President in 2006.

8

9

Evolving Distribution ofFaculty Strengths in

Chemical Engineering Departments

John C. ChenC. R. Anderson Professor and Dean of Engineering, Emeritus

Lehigh UniversityPast President, AIChE

AIChE Annual MeetingSan Francisco, November 2013

10

Premise

The collective interests, expertise and strengths/weaknesses of the faculty in departments of chemical engineering hassignificant influence on the capabilities and quality of theirgraduates and ultimately on the future of the profession.

Objective

Examine the current state and evolution of facultyinterests, expertise and strengths in US departmentsof chemical engineering.

11

Data BaseSample of 40 Departments, 708 FTE Faculty

Range of Departmental Characteristics: Public and Private Universities Undergraduate enrollment: 110 to 900 Graduate enrollment: 15 to 220 G/UG ratio: 0.06 to 0.81 Faculty FTE (current): 5 to 34 Emeritus Faculty FTE: 2 to 9 Rank by NRC for PhD programs: 1 to >20 Rank by USNWR for ChE: 1 to >60

12

Six “Baskets” of Subject Areas

UOUnit OperationsThermodynamicsTransport PhenomenaSeparationsParticle Technology& Related

REReaction EngineeringKineticsCatalysis& Related

AMAnalysis/ModelingSimulationProcess Control& Related

MatMaterial ScienceSurface SciencePolymers& Related

BioBio TechMedical ScienceLife Sciences& Related

NanoNano TechnologyNano Applications& Related

13

UO RE AM Mat Bio Nano0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

Strengths Among Current Faculty(620 FTEs in 40 Departments)

Conc

entr

ation

Am

ong

Facu

lty

FTE Concentration Relative Strength

Bio 28% 5 Mat 20% 4 UO 16% 3

AM 15% 2 RE 14% 2

Nano 7% 1

14

0-10% 10-20% 20-30% 30-40% >40%0.0

0.1

0.2

0.3

0.4

0.5 Concentration in Bio

% of Current Faculty in Bio

Frac

t. of

Dep

ts

Avg Highest 61.5 % Collective Avg 28.5 %Avg Lowest 8.6 %

0-10% 10-20% 20-30% >30%0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

Concentration in Nano

% of Current Faculty in Nano

Frac

t. of

Dep

ts


Distribution among Departments ?

0-10% 10-20% 20-30% >30%0.0

0.1

0.2

0.3

0.4

0.5Concentration in UO

% of Current Faculty in UO

Frac

t. of

Dep

ts


15

UO RE AM Mat Bio Nano0%

5%

10%

15%

20%

25%

30%

35%

40%

Concentration of Faculty StrengthsVarious Groupings

All 40 Depts

Highest 10 in USNW

Highest 10 in G/UG

Stre

ngth

in F

acul

ty

UO RE AM Mat Bio Nano0%

5%

10%

15%

20%

25%

30%

35%

Concentration of Faculty StrengthsEffect of UG Size

All 40 Depts

Smallest 10 in UG

Largest 10 in UG

Stre

ngth

in F

acul

ty

Differences for Sub-Groups ?

16

Emeritus Professor Associate Prof. Assitant Prof.0%

2%

4%

6%

8%

10%

12%

14%

16%

18%

Faculty Strength in RE

Evolution over Time --->

% in

Eac

h Ra

nk


5%

10%

15%

20%

Faculty Strength in AM


% in

Eac

h Ra

nk


5%

10%

15%

20%

25%

Faculty Strength in Mat


% in

Eac

h Ra

nk

Evolutionary Trend ?

17


5%

10%

15%

20%

25%

30%

35%

40%

Faculty Strength in Bio


% in

Eac

h Ra

nk


5%

10%

15%20%

25%

30%35%

40%

45%50%

Faculty Strength in UO

Evolution over Time ---->

% in

Eac

h Ra

nk


5%

10%

15%

20%

Faculty Strength in Nano


5 in

Eac

h Ra

nk

Evolutionary Trend ?

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Concluding Observations

Significant differences among departments exist in concentration of faculty strengths for 5 of the 6 subject areas (UO, RE, AM, Mat, Bio), varying from 0% to >30%.

Exception is the newer subject area of Nano, where no department has concentration >20%, and ~ ¾ of departments have <10% of their faculty expertise.

The concentrations for current faculty in all departments, show greatest strength in Bio – where a collective 29% of faculty is concentrated, with a number of depts having >62%.

The second strongest area is Mat – with a collective concentration of 19%.

For the “cores” areas of UO, RE, and AM, the collective strengths among currentfaculty are uniformly moderate – with concentrations in range of 14% to 16%.

Departmental ranking, size, or emphasis on graduate education do not appear to effect distribution of faculty strengths, significantly.

The most significant evolutionary changes of faculty strength are the substantial and continuing growth in Bio and the decline in UO.

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Implications for Discussion

Quality and relevance of ChE education

Competence of graduates

Preparation of young professionals

Choices for advanced studies

Future directions for ChE profession

Next

Engineering managers from three of the most important industries will discuss the strengths they seek in their chemical engineering staffs.Each will rate the importance they ascribe to the six subject areas, for thechemical engineering functions in their specific industry. How do theseratings compare to distribution of faculty strengths?

Chemical Engineering Skills for the Global Chemical Industry

Dr. Rui Vogt Alves da Cruz Director of Research and Development

Dow Chemical Company

Dr. Cruz has worked at both international and national locales for Dow. His responsibilities have ranged over Human Resources, Technical Services, Customer Services, and Research and Development, for several different products and technologies.Most recently, he was Group Leader for Polygcols and Surfactants R&D, before assuming role of Associate Director for R&D for Epoxy Process, Amines and Chelants and Plastic Additives. Dr. Cruz has been responsible for the recruitment of chemical engineering PhDs for the Materials Division of Dow Chemical Company since 2011.

20

Chemical Engineering Skills for the Global Chemical IndustryCurrent and Future Needs

Rui Vogt Alves da CruzThe Dow Chemical CompanyR&D Director

22

Chemical Engineers in the Chemical Industry

Engineering and Design

Manufacturing Research and Development

Marketing,Sales,

Finance,IT

Supply Chain,Business

Management

23

And some of the projects they work on

Engineering and Design

Manufacturing Research and Development

•Design and build a new cracker

•Develop tools for equipment specification

•Start-up and run the first world scale plant using a new process

• Implement process improvements to reduce waste generation

•Develop a process to produce a new molecule

•Screen new catalysts for improved yield and selectivity

24

93 respondents (ChemE recruiters

and leaders)

Skill

Average Relative

Importance 1-5

UO: unit operations, transport phenomena, thermodynamics, separation processes * 4.6

RE: reaction engineering, catalysis, kinetics. 4.0AM: analysis, modeling, simulation, process control * 4.0

MAT: materials, surface science, polymers * 3.2BIO: biotechnology, medical and life sciences 2.1NANO: nanotechnology and its applications 1.8

DOW RESTRICTED - For internal use only

* main perceived gaps between importance and proficiency by new hires

Survey on importance of skills

Manufacturing49%

Engineering22%

R&D29%

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Additional competencies and specific skills

SkillRelative

Importance 1-5

Communication and presentation skills ** 4.7

Project management ** 4.3

Process and lab safety ** 4.2

Equipment design and instrumentation 3.9

Design of experiment and statistics ** 3.8Programming skills 3.4Analytical methods 3.3

DOW RESTRICTED - For internal use only

** major perceived gaps between importance and proficiency by new hires

26

Main concerns and opportunities

•Coursework and project opportunities around application of chemical engineering fundamentals

•Foster learning and collaboration with other sciences and departments

• Industrial internships and co-op assignments

• Intimacy with equipment and mechanical skills

•Particle technology and solids handling

•Applied statistics and experimental design

•Problem solving skills•Communication, especially on technical matters

•Process safety, especially on reaction engineering

•Finance, process economics

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A fascinating control problem

The Future

Assessment of current skills

Forecasting of skills needed

Assessment of current skills

Identification of Gaps

Action Plan

Development of curriculum and

faculty

Implementation of changes

First bachelors under new program

First PhDs under new program

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Conclusions – Needs of the Chemical Industry

• Solid fundamentals in Unit Operations, Reaction

Engineering, and Analysis and Modeling are critical

• Multidisciplinary interests, versatility and problem solving

skills

• Industry and Academia must collaborate fast on

implementing the changes needed to prepare students for

future challenges

Petroleum Industry’s Need for Chemical Engineering Talent

Dr. Ashok KrishnaVice President of Technology, Downstream & Chemicals

Chevron Corporation

Dr. Krishna is responsible for development and deployment of non-IT technologies in Downstream & Chemicals for Chevron Corporation. Prior to his current appointment, he served as General Manager of Technology for Global Refining, and as Managing Director of Technology Marketing. Dr. Krishna has held technical leadership positions for most petroleum refining processes, including FCC, Thermal Processing, Rheniforming, Alkylation, and all aspects of Hydroprocessing. He is a member on the Boards for joint ventures between Chevron and Grace Davison, CBI Lummus, and Weyerhaeuser.

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© 2013 Chevron U.S.A. Inc. All rights reserved. 31

Chemical Engineering Skill Sets, Status, Needs, and Trends

Ashok KrishnaChevron Global DownstreamVice President, Technology

American Institute of Chemical Engineers (AIChE)2013 AIChE Annual Meeting November 4, 2013


Escravos Gas-to-Liquids Plant in NigeriaChevron Richmond Technology Center in Richmond, California

Chevron Sites

Karen DeLong

I couldn't locate any GTL photos for Qatar on CIL so I picked EGTL


The Skill Sets As We Define Them

UO: Unit operations, transport phenomena, thermodynamics, separation processes, and related

RE: Reaction engineering, catalysis, kinetics, and related

AM: Analysis, modeling, simulation, process control, and related

MAT: Materials, surface science, polymers, and related

BIO: Biotechnology, medical and life sciences

NANO: Nanotechnology and its applications

PE: Process engineering/design and process safety

BS: Business skills, technical writing, presentations, and communications


Relative Importance of Skill Sets to Us

SkillRelative

ImportanceDegree of

Preparation

BIO Low Medium

NANO Low Medium

RE Medium-High Medium

MAT Medium-High Low

BS High Medium

AM High Medium

UO High High

PE High Medium










Relative Importance of Skill Sets to Us









• New Materials/Catalysis will continue to be very important• We see a gap in process safety in general• Process Control education has to evolve as well

BIO

Nano

RE

MAT

BS

AM

UO

PE

0 1 2 3 4 5 6 7 8 9 10

Degree of Preparation

Relative Importance


Where We Use These Skill Sets

Note that it is common to start in Downstream and move to Upstream.


Control Rooms 30 Years Ago!


Control Rooms Today

Future Trends Need improved engineering economics knowledge (The Energy

Equation and needing ALL forms of energy), and a keen awareness of the evolving regulatory landscape and climate change.

We will continue to provide a majority of the energy that the world needs as developing countries improve their economies for decades to come, and need ChE skills.

Global Energy Mix, MMBOED

0

50

100

150

200

250

300

350

400

2000 2005 2010 2015 2020 2025 2030


Conclusions

With Integrated Oils, there is going to be a significantly higher demand for engineers in Upstream than

in Downstream

In downstream, hiring fell off in 2008-10 due to the global economic turndown, but has since recovered;

hiring rates will be healthy over the next decade as we replace an aging workforce and backfill behind

the retirement wave that is coming, transfer larger numbers of well-trained engineers to our Upstream

operations (for Integrated Oils), and support growth in the petrochemical industry

We will continue to need chemical engineers that are taught basic Unit Ops, and process design;

process safety training will become increasingly important as PSM will dominate our industry

Catalysts will continue to improve and provide yield benefits while increasing unit cycle lengths,

needing graduates to be well equipped in reactor science and catalysis

Increasingly, advanced automation and process control, safety instrumented systems, and real time

optimization will become more important. Engineers need to be taught not only the basics of process

control, but also be familiar with the latest in the hardware and the process control network.

Consumer-driven technology (handhelds, ruggedized tablets, wearables, etc.) will become commonly

deployed; luckily the younger generation of engineers comes well equipped in this regard

Future engineers will need to be well-versed in business skills and communications even more, be

aware of environmental regulations, and learn to operate as team members in a collaborative fashion

with operators, mechanics and optimization engineers in a central control room setting

Chemical Engineering Skills Sought by

Pharmaceutical Industry

Dr. Steven PoehleinPrincipal

Elixia Pharma Consulting, LLC

Dr. Poehlein has held various management positions at Merk, including that of Director for Technical Operations at several plants, Senior Director and Executive Director for Pharmaceutical Tech Operations, and Vice President for Global Technical Operations. He has been responsible for the technical support of some 80 manufacturing sites in more than 20 countries. The work of several hundred engineers and scientists in his organizations has ranged from process development, to manufacturing and packaging, to statistical modeling and analysis. He is an active member of the advisory committees for a number of chemical engineering departments at US universities.

41

Chemical Engineering Skills Sought by Pharmaceutical Industry

Steven Poehlein, PhDPrincipal, Elixir Pharma Consulting LLC

Previous – VP Global Technical Operations, Merck

Landscape of Pharma IndustryDiversity of unit ops, processes and products is large

and growing considering processes used for:Active Pharmaceutical IngredientsExcipientsFormulated ProductsPackages

Challenges abound in the industry including need to:Cut process development and manufacturing costs to

fund research and improve access to medicinesDevelop safer, more effective drugs and vaccinesMaximize returns during shrinking patent exclusivity

period

Landscape - continuedSupply chains can be complex given global

nature of business and manufacturing expertise

Process control strategies vary from fully automated to highly manual

Regulatory agencies increasing demands for FIRST principle understanding of manufacturing processes as related to true product quality attributes

Conclusion – Chemical Engineers remain highly relevant and necessary for pharma success

What does pharma need in today’s ChE Graduates?It’s all about the fundamentals, the entry

ticket!Demonstrated ability to apply fundamentals

to new unit operations and control strategiesLiteracy in process economics and cost

structuresAbility to work cross functionallyAbility to translate process technology to

either manual or automated plantsDeeper understanding of analytics and

measurements

Ancillary and Soft SkillsProcess safetyStatistical and empirical methods6 Sigma and analytical problem solvingLEAN ManufacturingCommunicationLeadershipDiversity and cross cultural exposure

Fundamental Gaps Still ExistPowder and Solid Processing

BlendingFlow and segregationGranulationTablet Compression

Stability of Formulated ProductsBioavailability as a function of product attributes

and controllable process parameters

Knowledge in these areas will improve the safety and efficacy of new and existing drug products.

A Challenge to ChE Faculty and Industry ExecutivesChE Faculty – Given limited curriculum real estate

and time, how do we:Introduce relevant new processes/unit ops into course

framework without compromising the fundamentals?Expose students to the power of cross functional

collaboration?Further develop the student’s soft skills?

Industry Executives – Given shrinking budgets, how do we:Support continued learning of soft and hard skills

throughout career?Increase partnerships with academia to improve

fundamental understanding of pharma processes?

Expertise Required of Chemical Engineers in Pharmaceutical Industry

UO (unit operations, transport phenomena, thermodynamics, separation processes, and related)

RE (reaction engineering, catalysis, kinetics, and related)

AM (analysis, modeling, simulation, process control, and related)

MAT (materials, surface science, polymers, and related)

BIO (biotechnology, medical and life sciences)

NANO (nanotechnology and its applications)

Importance (1 – 5)

5

5

4

3

4

2

Open Discussion

Questions and comments are invited fromthe assembly.

Please come to the floor microphones and

state your name and affiliation.

Moderator:Dr. Jennifer S. CurtisDistinguished Professor & Associate Dean of EngineeringUniversity of FloridaPast Director, AIChE

50

UO RE AM Mat Bio Nano0

1

2

3

4

5

Relative Importance of Subject Areas

ChemicalPetroleumPharmaceuticalCurrent FacultyAssistant Prof

Impo

rtan

ce

Current Faculty Assistant Profs Chem. Industry Petroleum Industry Pharma Industry(40 depts) (40 depts) (Cruz, Dow Chem) (Krishna, Chevron) (Poehlein, Merk)

UO 3 1 5 5 5RE 2 3 4 4 5AM 2 2 4 5 4Mat 4 3 3 4 3Bio 5 5 2 2 4

Nano 1 1 2 2 2

Chemical Engineering Expertise in Academe and as Sought by Industry

Session #97 (Plenary) Monday November 4 11 am-12:30 pm

Grand Ballroom A (Hilton)

Chair: John C. Chen (Lehigh University)Co-chair: James C. Hill (Iowa State University)

Sponsored by: AIChE Council of Fellows AIChE Keynotes & Plenaries AIChE Education Division Council for Chemical Research

Other sessions of possible interest:

Session #513 “Responding to Industry’s Needs”Sponsored by Education Division & YP CommitteeChair: Donald P. Visco Jr. Co-chair: Nemoy RauWednesday 12:30 pm—Union Square 24 (Hilton)

Session #140 “Effective Industry-University Partnerships ” Sponsored by Council for Chemical Research, AIChE Keynotes & PlenariesChair: Jennifer S. Curtis Co-chair: Clare McCabeMonday 12:30 pm—Grand Ballroom A (Hilton)

54

Additional Slides(Use in discussion as appropriate)

55

UO RE AM Mat Bio Nano0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

30.0%

Strengths Among Current Faculty(620 FTEs in 40 Departments)

Subject Areas

Conc

entr

ation

Am

ong

Facu

ltyCurrent distribution of faculty expertise and strengths ?

UO RE AM Mat Bio Nano0

1

2

3

4

5

Relative Importance of Subject Areas

ChemicalPetroleumPharmaceuticalCurrent FacultyAssistant Prof

Impo

rtan

ce

Observations:

• Mat --- fairly good correspondence between industry and academe.

• UO, RE, AM, Nano – all more important in industry than academe; greatest disparity is UO, where young faculty are week.

• Bio --- disparity shown, more important to academe than to industry.

57

0-10% 10-20% 20-30% >30%0.0

0.1

0.2

0.3

0.4

0.5

Concentration in UO

% of Current Faculty in UO

Frac

t. of

Dep

ts


0-10% 10-20% 20-30% >30%0.0

0.1

0.2

0.3

0.4

0.5Concentration in RE

% of Current Faculty in RE

Frac

t. of

Dep

ts


0-10% 10-20% 20-30% >30%0.0

0.1

0.2

0.3

0.4

0.5

Concentration in AM

% of Current Faculty in AM

Frac

t. of

Dep

ts


0-10% 10-20% 20-30% >30%0.0

0.1

0.2

0.3

0.4

0.5

Concentration in Mat

% of Current Faculty in Mat

Fra

ct. o

f Dep

ts


Distribution among Departments ?

chemical engineering expertise in academe and as sought by industry session #97 (plenary) monday...

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