what does a chem e do? engr10 guest lecture carlos casillas, ms, pe 11-03-11

What does a Chem E do?

Engr10 Guest Lecture

Carlos Casillas, MS, PE

11-03-11

Carlos Casillas 11-03-11 Engr10_What does a Chem E do?

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Outline

• Background• Definitions• Work experience

– Nanotechnology– Thin films– Polymer membrane separations

• ChE’s job roles– Upper division education


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Educational, Internship Background

School Major Degree Year

Engineering A. A. 1981

B. S. 1983

M. S. 1985

Certificate Year

Engineer-in-Training (EIT) 1982

Registered Professional Engineer (PE), State of CA 1996

Summer Internship Year

Dow Chemical Co. 1982

Mobil Chemical Co. 1983

Jr. Engineer

Summer Engineer

Chemical Engineering

Position

Chemical Engineering

Stanford University

Field

General Engineering


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Employment History

Employer#

peopleIndustry Position Years

70 NanotechnologyProcess Engineer/ Research Engineer

05-11

>5,000 Data StorageManufacturing Engineer, Thin-Film Head Process

00-05

Novellus Systems, Inc. >3,000Semiconductor Process Equipment Manufacturer

Process Engineer 96-00

60 Membrane Separations Research Engineer 91-96

Watkins-Johnson Co. >1,000Semiconductor Process Equipment Manufacturer

Process Engineer/ Member of Technical Staff

88-91

>5,000Semiconductor Manufacturer

Project Engineer 87-88

30LED Manufacturer

StartupProcess Engineer 85-87


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Wikipedia’s Definitions

• Chemical Engineering– The branch of engineering that deals with the technology of large-

scale chemical production and the manufacture of products through chemical processes.

• Chemical Engineer– One who applies and uses principles of chemical engineering in any

of various practical applications; primarily with respect to the design, manufacture, and operation of plant and machinery in industrial chemical and related processes.

– Modern chemical engineers are becoming more heavily involved in the development of new technologies such as fuel cells, hydrogen power and nanotechnology, as well as working in fields such as polymer engineering and biomedical engineering.

http://en.wikipedia.org/wiki/Chemical_engineering

http://en.wikipedia.org/wiki/Fuel_cells

http://en.wikipedia.org/wiki/Hydrogen_power

http://en.wikipedia.org/wiki/Nanotechnology

http://en.wikipedia.org/wiki/Polymer_engineering

http://en.wikipedia.org/wiki/Biomedical_engineering


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Area #1 Nanotechnology

Sample Nanomaterials (Images from NanoLab, Inc.)


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Quantum Dots/Nanocrystals enhance colors in LCD’s


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Quantum Dots enhance colors in LCD’s

Diameter of nanocrystals determines wavelength of emitted light when stimulated with blue LED radiation


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Nanomaterial Synthesis/Growth – liquid phase

Chemical reactor scale-up:

From lab (grams) to pilot-plant (kg) sized batches


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Nanomaterial Synthesis/Growth – solid/gas phases

• Fluidized bed CVD reactor for CNT’s


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Nanomaterial Synthesis – commercial CVD system

• jykjy


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Area #2 Semiconductor/Microelectronics Manufacturing Processes

• >20,000 sequential steps, class 1 clean room fab

• >80% Chemical engineers = process development, optimization, sustaining

• Chemistry Thin film coatings, etch, front-end processes, cleaning, photolithography, electroplating, CMP

• Materials Science, Physics Film properties, metrology

Thin Films

Photo-lithography

Cleaning

Front-EndProcesses

EtchIonImplantation

Planarization

Test &Assembly

DesignSilicon WaferPreparation

1999 Univ. of Arizona NSF/SRC Engrng Research Center (C.T.Sorenson/ Praxair, Inc.)


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Commercial Chemical Vapor Deposition (CVD) Reactors

• Plasma-Enhanced (PECVD) Dielectrics (TEOS, Nitride)

• High-Density Plasma (HDP) Oxide, Nitride

• Atmospheric-Pressure (APCVD) TEOS/O3

• Low-Pressure (CVD) W– Process Chamber

Cleaning (Plasma Etching, PFC’s)

• Physical Vapor Deposition (PVD) Conductors, Diffusion Barriers (Al, Cu, TiN, Ta, etc)

LPCVDChamber

TransferChamber

Gas Inlet

Exhaust

RF Power

Wafer

MeteringPump

Inert MixingGas

Process Gas

Vaporizer

DirectLiquid

Injection

TEOSSource

Cluster ToolConfiguration

TransferChamber

Loadlock

Wafers

CVD or PVDDepositionChambers

SIDE

TOP


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Area #3 Membrane Separations Technology


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Membrane Gas/Vapor Permeability Measurement

• Membrane Stamp Permeation Test Apparatus

GC/ FID

HUMIDITY SENSOR

INERT GAS CYLINDER

VAPOR CARRIERS:

PRESSURE REGULATOR

VENT

MIXING TUBE

P

P

RH/ T

MEMBRANE TEST CELL

DATA LOG

MFC

MASS FLOW CONTROLLERS: DILUTION

MFC

MFC

VOC 1 BUBBLER

VOC 2 BUBBLER


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Membrane Gas/Vapor Permeability Measurement, con’t

• Membrane Stamp Permeation Test Apparatus

DIFFERENTIAL PRESSURE SENSOR

FLOW CAL TUBE HUMIDITY SENSOR

VOC 2 BUBBLER

VOC 1 BUBBLER MEMBRANE TEST CELL

GC/ FID

MFC POWER & ELECTRONICS

PRESSURE GAUGE

FLOW ROTA-METERS

MFC’s


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Membrane Module Configurations

(c) Hollow-fiber Module


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Commercial Membrane Liquid Separations Systems

• Hemodialysis (kidney)

• Blood filtration• Asymmetric,

microporous UF membrane

• Hollow fibers


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Industrial Gas Separation Membrane Systems


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Successful Traits, Skills in Engineers

• Creative Inquisitive, detail-oriented, wants to understand how it works, come up w/ideas

• Problem solver Enjoys overcoming tough technical challenges, perseverant; uses math, chemistry, physics & engineering training

• Practical Good judgment, simplest approach 1st, hands-on work w/chemicals, equipment

• Team player Communicates well (verbal & in writing), gets along with colleagues, project goals come 1st

• Conscientious Dependable, plans ahead, organized, methodical, meets commitments


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Industries employing ChE’s

• Petrochemicals Bulk & specialty chemicals, gases, polymers, pharmaceuticals, etc

• Energy Petroleum, coal, gas, nuclear, fuel cell, renewable (solar, synfuels, biofuels), etc

• Advanced materials Microelectronics, data storage, nanotechnology, photonics, etc

• Biotechnology/ biomedical Medical technology

• Environmental Exhaust & waste treatment, site remediation, resource recycle

• Mining


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ChE’s Job Functions

• R&D New materials development, characterization, experiment design, analysis

• Product economic feasibility/ analysis– Marketing/ sales/ business development

• Scale up / plant design – computer modeling, pilot-plant testing, validation

• Industrial scale process equipment qualification, implementation

• Manufacturing process engineering/ continuous improvement/ sustaining operations– Product quality, reliability characterization

• Project/ program management/ technical lead• Teaching• Consulting


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ChE’s Team Members• Manager• Other engineers:

– MS&E’s Materials/device analysis, process engineers– ME’s Hardware, instrumentation design, fabrication, testing– EE’s, CS’s Software, controls, device design, testing– IE’s Manufacturing, productivity– EnvE’s, EH&S Safety, waste or exhaust abatement– CE’s Structural

• Scientists Chemists, physicists, biochemists, biologists, biomedical technologists, etc

• Marketing customer support, sales/ business people• Technicians research, process, maintenance• Operators equipment / plant• External suppliers, partners, customers


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ChE’s Education• 4-yr University degree (BS) last 2 years:

– Upper-division engr (Intro Thermodynamics, Fluid Mechanics) & core Chem E req’s:

• Physical Chemistry, Math (PDE’s, Vector Calculus, Linear Algebra, Numerical Methods), Engr Statistics, Engr Economics, 2nd Programming language, etc

– ChE Core:• Chemical Thermodynamics/ Separations Processes• Chemical Reaction Engr/ Kinetics• Momentum, Heat & Mass Transport• Process Dynamics & Control• ChE Plant Design, ChE Lab• Nanotechnology, Bioengineering, or Polymer Science


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(Appendix) Education / Training

• 2-yr Community College degree (AA, AS)– Lower-division engr & GE req’s:– Chemistry (General, Organic, Quant), Physics– Math (Calculus, ODE’s)– Engr fundamentals:

• Engr Graphics• Engr Mechanics/ Statics• Properties of Materials• Circuit Analysis• Computer Programming

– English comp, speech, humanities courses, etc


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(Appendix) Education / Training, con’t• Graduate degree (MS)

– Grad Chem E courses:• Chemical Thermodynamics• Heterogeneous Catalysis/ Surface Science• Heat & Mass Transfer• Mathematical Methods in ChE• Fluid Mechanics• Combustion Engr

– Other Grad Engr courses:• Integrated Circuit Fabrication Processes• Semiconductor Device Physics• Materials Science of Thin Films• Electronic Properties of Materials• Thermal Physics

what does a chem e do? engr10 guest lecture carlos casillas, ms, pe 11-03-11

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