Process Design Engineer Interview Questions and Answers

One problem I faced was flooding in the distillation column.

• Flooding occurs when the liquid flow rate exceeds the capacity of the column to handle it.

• This can lead to reduced separation efficiency and even damage to the column internals.

• To prevent flooding, I adjusted the liquid flow rate and made sure the column was properly designed for the specific process conditions.

Heat exchanger and column design are crucial for efficient plant operation.

• Heat exchanger design involves selecting appropriate materials, determining heat transfer coefficients, and calculating pressure drops.

• Column design involves determining the appropriate tray or packing design, sizing the column, and selecting the appropriate reflux ratio.

• Both designs are related to the specific plant and its process requirements.

• Efficient heat exchanger and column design can lead to si...read more

P&ID shows detailed piping and instrumentation information, while PFD shows overall process flow.

• P&ID includes detailed information on piping, instrumentation, equipment, and control systems.

• PFD provides an overview of the entire process flow, showing major equipment and key control points.

• P&ID is used for detailed design, construction, and operation of the process plant.

• PFD is used for understanding the overall process flow and identifying major equipment.

• P&ID typically incl...read more

Various instruments are used in the plant for monitoring and controlling the process.

• Pressure gauges for measuring pressure

• Temperature sensors for measuring temperature

• Flow meters for measuring flow rate

• Level sensors for measuring liquid level

• Control valves for regulating flow

• Analyzers for measuring chemical composition

• PLCs for controlling the process

• SCADA systems for monitoring the process

• Safety instruments for emergency shutdown

• Vibration sensors for monitoring equipment hea...read more

Process design involves creating efficient systems for manufacturing or service delivery, optimizing resources and workflows.

• Involves defining the steps and resources needed for a process.

• Focuses on efficiency, safety, and cost-effectiveness.

• Example: Designing a chemical production process to maximize yield.

• Includes selecting equipment, materials, and technology.

• Example: Choosing the right reactor type for a specific reaction.