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• Dr Ali Nabavi

The module provides the essential knowledge and hands-on skills for design and development of gas separation and purification technologies that are required for the decarbonisation of power and industry sectors, as the prerequisite to meet the net-zero emission target. 

The module enables you to master the underlying mechanisms of sorption and separation processes, along with the required experimental characterisation and data analysis techniques, and computational modelling. This knowledge will then be applied to design, develop, and evaluate carbon dioxide separation in power (i.e. gas and coal power plants) and industrial (i.e cement, iron and steel) sectors; biogas upgrading; hydrogen purification, and carbon dioxide and hydrogen storage, as case studies. 

 

• Principles of gas separation and purification:
  • Gas-liquid absorption/adsorption principles, 
  • Equilibrium and kinetic adsorption principles.
• Sorbent characterisation:
  • Design of experiments for characterisation of sorbents for separation and purification processes,
  • Characterisation of non-functional and functional sorbents using techniques such as scanning electron microscopy – energy-dispersive X-ray spectroscopy (SEM-EDX), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), Brunauer-Emmett-Teller (BET) surface area analysis and Barrett-Joyner-Halenda (BJH) pore size and volume analysis,
  • Data analysis techniques.
• Design and evaluation of gas separation, purification and storage technologies to achieve net-zero emission target:
  • Carbon dioxide separation in power and industrial sectors,
  • Biogas upgrading,
  • Hydrogen purification,
  • Direct air capture.
• Case Studies:
  • Case studies will be carried out using the acquired experimental data, and process simulations.

On successful completion of this module you should be able to:

• Apply the principles of gas adsorption and absorption in the design of separation and purification units,
• Characterise an analysis sorbents for the gas separation process,
• Critically evaluate the main challenges of carbon dioxide and hydrogen separation and storage in the energy sectors,
• Design and optimise separation and purification processes, contributing to achieving net-zero emission target. 

• Dr Mingming Zhu

This module is designed to give the students an advanced understanding of reaction kinetics, catalytic and non-catalytic gas-solid reactions, heat and mass transfer phenomena governing chemical reactions in energy engineering applications and experimental methods for kinetic measurements. The module also provide them with transferable skills in applications of reaction rate in reactor design and machine learning technique for catalyst/material design.

You will understand basics of reaction kinetics and thermodynamics and will learn how to design appropriate experimental methods to measure kinetics. 
 
You will learn how to model gas-solid reaction systems covering catalytic heterogenous reactions and non-catalytic reactions relevant to energy such as combustion, gasification, hydrogen production and CO2 capture. Within this breadth of systems, you will investigate the important role of mass and heat transfer in chemical reaction process in order to observe rate limiting steps to enhance/ chemical reactions.
 
You will learn new skills in using Chemkin to solve complex reaction systems and how to combine both reaction kinetics, transport and thermodynamic data into solving real problems that controlled by reaction kinetics such as hydrogen combustion and pollutants formation. 
 
You will also learn the latest research that is being undertaken to design new catalytic materials involving first-principals modelling aided by machine learning. You will learn of catalytic material synthesis methods and how these processes can be optimised for industrial applications. 

On successful completion of this module you should be able to:

• Critique different kinetic models and develop coherent and professional arguments that communicate how one could enhance overall reaction rates by overcoming rate limiting steps or properties of the solid material.
• Implement detailed kinetic reaction mechanisms in Chemkin and conduct sensitivity analysis.
• Design experimental methods to measure kinetics of gas-solid reactions and evaluate the effect of gas diffusion, reaction kinetics, and mass and heat transfer phenomena and the limits of knowledge/applicability in these areas.
• Apply latest machine learning technique to design catalysts and understand reaction mechanism.

• Dr Stuart Wagland

The module focuses on the opportunities for the conversion of biomass and waste to energy; industry-focused, providing you with a critical understanding of the key challenges in operating energy from waste facilities.  The module consists of visits to modern waste management facilities which include talks from the managers at each site to cover the day-to-day management of such technologies and aims to provide you with advanced knowledge of the sources of biomass and waste, and the range of technologies available for their conversion into energy, particularly focused on thermochemical conversion whereby opportunities for producing alternative fuels and chemicals from wastes will be explored. You will conduct laboratory exercises to characterise solid fuels (e.g. waste feedstock and solid residues), assessing the composition and characteristics of waste materials to critically evaluate the fuel properties of the samples.  Using analytical results to design thermochemical energy conversion systems using chemical modelling software (e.g. Aspen Plus).
 
Furthermore, the module provides you with a critical understanding of the key differences and challenges in pilot-scale working. The module will utilise several facilities at Cranfield as part of the taught sessions in addition to a visit to an external site, such as a waste management facility, to collect samples for analysis in the laboratory.  As a practical module, you will gain significant practical experience through lab practical sessions, computer simulation and industrial site visits.

Policies driving and regulating thermal conversion (gasification and pyrolysis) and incineration technologies;

Understanding how and why waste composition changes and the effects of these changes on the energy potential.  Explored further as part of a practical session covering waste and waste-derived fuel characterisation;

Material characterisation (elemental analysis, calorific value, thermal decomposition (TGA) and analytical skills for fuel products characterisation).

Principles and reaction mechanisms of Gasification, pyrolysis and Combustion.

Design principles of thermochemical processes and appropriate full energy system integration

Facility management challenges including process and emissions monitoring, health and safety compliance, and maintenance routines;

Management of post-energy recovery residues (bottom ash, fly ash, digestate etc)

Complex chemical and thermal process modelling using ASPEN Plus

On successful completion of this module you should be able to:

1. Characterise and select the most appropriate biomass and waste materials for energy conversion applications,
2. Design and assess appropriate energy conversion systems for bioenergy production from biomass and waste,
3. Develop and apply analytical skills to carry out process simulation for design of energy conversion systems,
4. Critically evaluate the main operational challenges in operating thermochemical processes, reviewing current practice to identify potential areas for research and development,
5. Critically evaluate the application of software packages relevant to chemical engineering for upscale design from pilot-scale results to demonstration and commercial scale plants.

• Dr Adriana Encinas-Oropesa

The purpose of this module is to provide you with experience of planning a project that will involve scoping and designing a product.  The module provides sessions on project and planning, including sustainable design principles, project risk management and resource allocation. A key part of this module is the consideration of systems thinking approach for creating innovative solutions, ethics, professional conduct, and the role of an engineer within the wider industry context as well as considerations for equality, diversity and inclusion.

Project Management,
Ethics, EDI and the role of the engineering (ethics case study),
Product development,
Circular Economy,
Systems thinking,
Innovation.

On successful completion of this module you should be able to:

• Apply design thinking methods and techniques to generate a product design concept that can be scaled up to a commercially viable solution.
• Design and plan the product project including processes, resources required (human and material), product end-of-life and risk management.
• Integrate systems thinking and circular economy approaches to develop sustainable and innovative products.
• Evaluate ethical dilemmas, equality, diversity and inclusion (EDI), and the role of the engineer within the context of their chosen industry.

• Dr Navid Khallaghi

This module provides students with advanced knowledge and hands-on experience in modelling, evaluating, and optimising chemical engineering systems. Students will work with Aspen Plus for process simulation, conduct techno-economic and life cycle assessments, and apply machine learning techniques for system analysis and predictive modelling. The concept of digital twins is introduced to bridge simulation models with real-time data for intelligent process monitoring and optimisation. This skill set supports evidence-based decision-making for sustainable and cost-effective process design and operation, aligning with current industry trends in chemical manufacturing.

Process Modelling with Aspen Plus
• Process flow-sheeting, steady-state simulation, data input/output, and design scenarios.
• Process optimisation techniques
• Case Studies: Process design, simulation and optimisation case studies based on industrial or research projects
Techno-economic assessment:
• Estimation of capital and operating costs.
• Economic indicators: NPV, IRR, and levelised cost of production
• Sensitivity and uncertainty analysis
Life Cycle Assessment:
• LCA methodology, goal and scope definition, inventory analysis, impact assessment
• Application to chemical processes using case studies

Machine learning for chemical engineering 

• Basics of supervised and unsupervised learning.
• Algorithms: regression, clustering, classification
• Implementation in MATLAB or Python for predictive analysis.
Digital Twin
• Introduction to digital twin concepts.
• Use of simulation models with real-time data.
• Applications in performance monitoring, fault detection, and decision support.

• Evaluate and simulate chemical processes using advanced process modelling tools.
• Apply techno-economic analysis to evaluate chemical process viability
• Assess environmental impacts through life cycle analysis methodologies.
• Apply machine learning tools for classification, prediction, and optimisation in chemical process datasets.
• Create digital twin frameworks for process monitoring and decision support

• Dr Ali Nabavi

Design of optimum thermal and energy storage systems is one of the key prerequisites to enhance the performance and efficiency of conventional and future energy systems and chemical processes.

This module aims to enable you to combine and apply the principles of heat transfer, thermodynamics and fluid mechanics in the design and optimisation of commercial thermal systems. In addition, the module introduces you to a wide range of challenges and opportunities in waste heat recovery and energy storage, and provides practical approaches and solutions to enhance the system efficiency.

Heat exchanger Design and Operation
Heat exchangers: Classification. Theoretical principles and design of recuperative systems (effectiveness, NTU and capacity ratio approach for parallel-, counter- and cross-flow configurations). Regenerative heat exchangers (intermittent and continuous systems). Heat exchanger optimisation (optimal pressure drop and surface area to maximise economic returns. Health and safety design considerations of heat exchangers.

Process integration: Problem table method. Heat-exchanger network. Utility systems. Fundamentals of pinch analysis and Energy Analysis.  

Refrigeration systems

Application of refrigeration

Vapour-compression refrigeration systems: Multi-stage compressor systems. Multi-evaporator systems.

Absorption refrigeration: Absorption refrigeration for waste heat recovery. The absorption process. Properties of fluid-pair solutions. Design of absorption cycles. Double-effect systems.  Advances in absorption-refrigeration technology.

Heat Recovery and Thermal Storage

Heat recovery: Heat recovery for industrial applications.

Thermal storage: Principles and application to hot and cold systems. Storage duration and scale. Sensible and latent heat systems.  Phase-change storage materials.  

Thermal system modelling

CFD modelling of thermal systems: Development and optimisation of CFD models for simulating thermal systems. Case studies for development of analytical solutions for design of thermal systems. 

On successful completion of this module you should be able to:

• Analyse and design heat exchangers, competently applying the principles of heat transfer, thermodynamics and fluid mechanics,
• Construct optimised heat exchanger networks by applying principles of process integration,
• Recognise and debate  the issues related to the efficient use of thermal energy and appraise  techniques and technologies employed,
• Design and analyse the performance of refrigeration and air conditioning systems.

• Dr Vinod Kumar

The Biofuels and Biorefining module focuses on bioproduction of fuels and chemicals as a sustainable, environmentally friendly and low cost route This bioproduction can contribute to decreased greenhouse gas emissions, by replacing petrochemical route and also fulfil the global goals on the use of renewable energy.

The aim of the module is to provide you with advanced knowledge of the sources of biomass available for production of a range of high value chemicals and technologies used for conversion of the biomass. The module covers characteristics of biomass as potential feedstock, bioproduction of fuel and chemicals, types of biorefineries, conversion processes and existing technologies. In addition, an introduction to the Biorefining concept will be provided.

Raw materials for production of bio-based chemicals, characterization and assessment
Biofuel feedstocks and characteristics: starch- and sugar- based biomass, oleaginous-based biomass, lignocellulosic biomass, glycerol and algae.
Sugar, Fatty acid, and Syngas platforms technologies

First generation biorefinery
Bioethanol production
Biobutanol production

Biodiesel production
Biodiesel production technologies: biochemical, and catalytic and non-catalytic chemical processes. 
Biodiesel production: biochemical aspects.
Biodiesel production: chemistry and thermodynamic aspects.

Lignocellulosic biorefinery
Bioethanol production
Bioproduction of succinic acid
Bioproduction of 2,3-Butanediol
Bioproduction of Lactic acid

Algal Biorefineries
Technologies for microalgal biomass production
Algal biofuels conversion technologies

Food waste biorefineries
Manufacturing Platform Chemicals from food wastes

Glycerol-based Biorefineries
Bioproduction of 1,-3-Propanediol
Bioproduction of 3-Hydroxypropionic acid


AD-based biorefineries
Biofuel production by AD
Possible feedstocks and challenges

Biorefining
Classification of Biorefineries
Economic, social and environmental impacts of biorefining

Commercial biorefineries

On successful completion of this module you should be able to:

State and assess the range of biomass resources/ biowastes/ agro-industrial wastes available for biofuels and biochemicals production;

Critically evaluate a range of technologies and biorefineries available for biofuels and biochemicals production from biomass and analyse the potential for future reduction in costs through technological development;

Explain the main theoretical concepts and practical implementation associated with bioproducts engineering systems;

Identify the high-value products that can be obtained from biomass feedstock.

Construct simple biorefining schemes and critically evaluate the potential of biorefining processes.

• Dr Sagar Jain

The Hydrogen Production module aims to equip you with a comprehensive understanding of the key engineering principles and challenges underpinning low-carbon hydrogen production. As hydrogen plays a central role in the transition to net zero, the module addresses the growing need for engineers who can apply chemical, electrochemical, and biochemical engineering knowledge to design efficient and scalable production processes. You will develop the skills to determine and assess performance indicators across thermochemical, electrochemical, and biological routes, and will critically evaluate real-world case studies. Emphasis is placed on the integration of technical feasibility with techno-economic, environmental, and socio-political considerations, enabling you to appraise production pathways and propose viable solutions for large-scale implementation. The module also supports you in understanding the critical steps and challenges involved in the commercialisation of hydrogen technologies, preparing you to contribute to the deployment of hydrogen solutions in real-world energy systems.

• Challenges and opportunities in hydrogen production: 
  Thermochemical hydrogen production
  Electrochemical hydrogen production
  Biochemical hydrogen production
• Technoeconomic and life cycle analysis of hydrogen production
• Socio-political issues associated with hydrogen production  

• Apply the principles of chemical, electrochemical, and biochemical engineering principles in the design of hydrogen production processes.
• Determine and evaluate key performance indicators (KPIs) for thermochemical, electrochemical, biochemical processes for low carbon hydrogen production
• Critically appraise complex chemical, electrochemical biochemical engineering case studies, analysing key challenges and developing know through of feasible solutions for delivering large-scale low carbon hydrogen production projects.
• Criticizing issues related to different hydrogen production approaches by means of techno-economics, lifecycle analysis and socio-political aspects