Process Control by Design with Excel Heat Exchanger Models

In chemical engineering, designing a system that works under steady-state conditions is only half the battle; you must also design it to be controllable. This text-based course guides you through the fundamental principles of process control by design, focusing on how physical equipment layout directly impacts controllability. You will learn how to evaluate and modify process networks to handle real-world disturbances. By studying the relationship between design and control, you will understand how to build resilient chemical engineering systems. What you'll learn: Understand the core principles of process control by design and how equipment selection influences system stability; Analyze heat exchanger networks using Excel spreadsheet models to identify control limitations; Configure bypass systems and trim heat exchangers within a basecase model to improve thermal control; Practice calculating process sensitivity to design modifications and external disturbances; Apply modern systematic design workflows to balance capital costs with process flexibility. The course begins with foundational definitions of process control, system dynamics, and heat integration. You will then progress through step-by-step written explanations of spreadsheet-based modeling, learning how to manipulate a basecase heat exchanger network to add control elements. This course is designed for undergraduate chemical engineering students, practicing process engineers, and technical professionals looking to understand the intersection of process design and control. No advanced simulation software is required, as all exercises are performed using standard Excel spreadsheet formulas.