Using Generative AI in Process Design, Chemical Engineering & Process Safety

Participants will learn how to apply generative AI in process design, chemical engineering, and process safety studies. They will develop skills in calculations, equipment sizing, control schemes, and documentation support. The course builds competence in HAZOP, LOPA, and safety instrumented system development with generative AI assistance. By the end, participants can integrate generative AI into engineering workflows while
ensuring validation against standards.

Day 1

Module 1: Introduction to generative AI in Process Engineering

1. Role of generative AI-powered tools in Chemical Engineering & Process Safety

2. Overview of generative AI capabilities, limitations, and reliability checks

3. Integrating generative AI with engineering workflows (simulation tools; HYSYS, UNISIM)

4. Importing Process Flow Scheme and P&ID in generative AI

Module 2: Process Design Fundamentals with generative AI

1. Material & Energy Balances (H&MB generation support)

2. Stream property predictions (enthalpy, phase, compositions)

3. Equipment design calculations:

• Heat exchangers (UA, LMTD, approach temperatures)
• Pumps & compressors (pump curves, surge line, NPSH)
• Distillation columns (McCabe-Thiele, shortcut distillation, tray efficiency)

Workshop: Using generative AI to draft a Heat & Material Balance for a Distillation column case study

Day 2

Module 3: Process Control & Automation

1. Control loop narratives (flow, pressure, temperature, level control)

2. P&ID development support and tag generation

3. Control valve sizing and pump minimum flow protection

4. Generative AI as Copilot for Dynamic Simulations in UNISIM/HYSYS

Module 4: Specialised Chemical Engineering Applications

1. Reactor kinetics support (CSTR, PFR, catalytic reactors)

2. Thermodynamics (VLE, EOS, property methods)

3. Separation technologies: distillation, membrane, adsorption, and extraction

4. Process intensification concepts

Workshop: Drafting a process control scheme for a Distillation column case study