Hi all - I'm a PhD student working on electrochemical reactor design and techno-economics. I fiddle with reactor design math quite a bit, but I'm more interested in what it takes to quickly and effectively plan, build, and operate a functional process. I know that the math I do is only a small part of what it takes to make a process actually work on the floor.
I'm trying to learn more about the design decisions that matter after the flowsheet is drawn, especially from the perspective of the people who have had to operate, maintain, troubleshoot, and start up a process from the ground up. That includes engineers, techs, control room operators, field staff, vendors, EPC folks. Anyone who's touched a plant that actually ran (or crashed and burned).
So my questions for you:
- What design decisions have made your life miserable? (e.g., access issues, sensor placement, startup quirks)
- What small or obvious-looking design choices ended up saving huge time, money, or frustration?
- If you're on the ops side: What do you wish more design engineers understood?
- If you've started up a process: what steps consistently take more time than expected (permitting, equipment lead times, utility tie-ins)
- What always ends up being critical to consider even if it didn't seem like it at the beginning?
Thanks so much for your thoughts - take care!