What does a Chem E do?
Engr10 Guest Lecture
Carlos Casillas, MS, PE
April 5, 2012
Outline
• Background
• Definitions
• Work experience
– Nanomaterials
– Thin films
– Polymer membrane separations
• ChE’s job roles
– Upper division education
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Educational, Internship Background
School
Stanford University
Major
Degree
Year
Engineering
A. A.
1981
B. S.
1983
M. S.
1985
Chemical
Engineering
Certificate
Field
Year
Engineer-in-Training (EIT)
General Engineering
1982
Registered Professional Engineer (PE), State of CA
Chemical Engineering
1996
Summer Internship
Position
Year
Dow Chemical Co.
Jr. Engineer
1982
Mobil Chemical Co.
Summer Engineer
1983
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Employment History
Employer
Novellus Systems, Inc.
Watkins-Johnson Co.
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#
people
Industry
Position
Years
70
Nanotechnology
Process Engineer/
Research Engineer
05-11
>5,000
Data Storage
Manufacturing Engineer,
Thin-Film Head Process
00-05
>3,000
Semiconductor Process
Equipment Manufacturer
Process Engineer
96-00
60
Membrane Separations
Research Engineer
91-96
>1,000
Semiconductor Process Process Engineer/ Member
88-91
Equipment Manufacturer
of Technical Staff
>5,000
Semiconductor
Manufacturer
Project Engineer
87-88
30
LED Manufacturer
Startup
Process Engineer
85-87
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Some Definitions
• Chemical Engineering
– The branch of engineering that deals with the technology of largescale 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.
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Area #1 Nanotechnology
Sample Nanomaterials (Images from NanoLab, Inc.)
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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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Quantum Dots/Nanocrystals enhance colors in LCD’s
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Hydrogen Fuel Cells
Pt or Pt alloy
nanocrystal
catalyst
2H2 → 4H+ + 4eO2 + 4e- + 4H+ → 2H2O
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5 nm
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porous support
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Energy Storage
• Enormous demand
• Li+ Batteries
– Carbon anode
specific capacity
<350 mAh/g
– Nominal “Moore’s
Law” 9 years
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Silicon
Specific capacity
10X > graphite
L
Li
• Stress/strain induced material degradation (up to 3X
volumetric expansion during lithiation)
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Si-NWs
Initial
Dia.
20nm
PostLithiation
Dia.
<33nm
• Does not disturb SEI
• Does not cause excess swelling
 Good cycle life
performance with increased capacity12
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Ex: Au-Si VLS (CVD) Si-Nanowire Growth Process
Au Nanoparticles
deposited
from colloid
solution 
NW density
& core size
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Control of Si-NW Morphology & Properties
• Growth process:
- Substrate temperature
- Total pressure
- SiH4 partial pressure
- Gas ratios
- Gas flow distribution
- Growth time
• Characterization:
- NW size, distribution
- Core/shell configuration
“Bird’s nest” tructure optimal porosity, mechanical strength
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Carbon Nanostructures
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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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Silica Nanogel (Aerogel)
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Area #2 Semiconductor/Microelectronics Manufacturing
Processes Silicon Wafer
• >20,000 sequential
steps, class 1 clean
room fab
• Materials Science,
Physics  Film
properties, metrology
Front-End
Processes
Thin Films
• >80%  Chemical
engineers = process
development,
optimization, sustaining
• Chemistry  Thin film
coatings, etch, front-end
processes, cleaning,
photolithography,
electroplating, CMP
Design
Preparation
Photolithography
Ion
Implantation
Cleaning
Etch
Planarization
Test &
Assembly
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1999 Univ. of Arizona NSF/SRC Engrng Research Center (C.T.Sorenson/ Praxair, Inc.)
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Commercial Chemical Vapor Deposition (CVD) Reactors
Cluster Tool
Configuration
• Plasma-Enhanced
TOP
(PECVD) Dielectrics
Wafers
(TEOS, Nitride)
• High-Density Plasma
(HDP) Oxide, Nitride
Metering Inert Mixing
• Atmospheric-Pressure
Gas
TEOS Pump
(APCVD) TEOS/O3 Source
• Low-Pressure (CVD) W
Vaporizer
– Process Chamber
Direct
Cleaning (Plasma
Liquid Process Gas
Etching, PFC’s)
Injection
• Physical Vapor
LPCVD
Gas Inlet
Deposition (PVD)
Chamber
Conductors, Diffusion
Wafer
Transfer
Barriers (Al, Cu, TiN, Ta,
Chamber
RF Power
etc)
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Exhaust
CVD or PVD
Deposition
Chambers
Transfer
Chamber
Loadlock
SIDE
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Thin Film Magnetic Storage
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Thin Film Magnetic Storage
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Area #3 Membrane Separations Technology
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Membrane Gas/Vapor Permeability Measurement
MASS FLOW CONTROLLERS:
DILUTION
MFC
PRESSURE
REGULATOR
P
MIXING
TUBE
MEMBRANE
TEST CELL
VAPOR
CARRIERS:
DATA LOG
HUMIDITY
SENSOR
RH/ T
MFC
VOC 1
BUBBLER
P
MFC
INERT GAS
CYLINDER
VOC 2
BUBBLER
GC/ FID
VENT
• Membrane Stamp Permeation Test Apparatus
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Membrane Gas/Vapor Permeability Measurement, con’t
DIFFERENTIAL
PRESSURE SENSOR
PRESSURE
GAUGE
FLOW CAL
TUBE
HUMIDITY SENSOR
FLOW
ROTAMETERS
• Membrane
Stamp
Permeation
Test
Apparatus
MFC’s
GC/
FID
VOC 2
BUBBLER
VOC 1 BUBBLER
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MEMBRANE
TEST CELL
MFC POWER &
ELECTRONICS
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Membrane Module Configurations
(c) Hollow-fiber Module
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Halon Vapor Recovery System
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Halon Vapor Recovery System
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Fluorocarbon Vapor Recovery System
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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
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