In my senior design project we sized a continuous stirred‑tank reactor (CSTR).

We needed to determine the required feed rates and heat removal to meet production targets.

I wrote the mass balance equations for each component, applied steady‑state assumptions, and coupled them with an energy balance accounting for reaction enthalpy and coolant duty.

The calculations gave us the optimal feed composition and cooling water flow, which we validated with a pilot run achieving 95% conversion.

During an interview for a process engineer role I was asked to compare reactor types.

Explain key operational and design distinctions.

I highlighted that batch reactors operate in discrete cycles with flexible scheduling, while continuous reactors run steady‑state, offering higher throughput and consistent product quality. I also mentioned differences in control strategies, equipment sizing, and suitability for hazardous reactions.

The interviewer noted my concise comparison and asked follow‑up on scale‑up considerations.

At my internship I was tasked with improving energy efficiency of a small polymer plant.

Perform pinch analysis to identify heat integration opportunities.

I gathered stream data, plotted composite curves, identified the pinch point, and proposed heat exchanger network modifications, including a heat cascade and utility reduction.

The redesign cut utility consumption by 18%, saving $120k annually and reducing CO₂ emissions.

In a research project we needed a catalyst for selective hydrogenation of a dienic compound.

Identify a catalyst that maximized selectivity while minimizing deactivation.

I reviewed literature, screened metal‑support combinations, performed lab tests for activity and selectivity, and evaluated catalyst life under process conditions.

We selected a Pd‑on‑Al₂O₃ catalyst achieving 92% selectivity and a 200‑hour run time, which was adopted for pilot scale.

During a safety audit I was asked to outline hazard control strategies.

Present the hierarchy of controls clearly to a mixed audience.

I described elimination, substitution, engineering controls, administrative controls, and PPE, providing examples for each within a chemical plant context.

The team adopted additional engineering controls, reducing incident reports by 12% over six months.

Our company planned to launch a new surfactant in the EU market.

Verify REACH registration and safety data requirements.

I performed a substance identification, gathered toxicological data, prepared a registration dossier, coordinated with a third‑party consultant, and submitted the dossier to ECHA within the deadline.

The product received REACH registration on time, enabling market entry without legal delays.

In my previous role the distillation column had a recurring capacity bottleneck affecting downstream units.

Lead a team of process, mechanical, and control engineers to increase throughput.

I organized a root‑cause analysis workshop, assigned tasks, facilitated weekly progress meetings, and implemented a column internals redesign with improved tray efficiency and upgraded control logic.

Throughput increased by 22%, downtime dropped by 30%, and the project was completed two weeks ahead of schedule.

During a pilot plant run a sudden exothermic runaway was detected in a reactor.

Decide immediate actions to protect personnel and equipment.

I initiated the emergency shutdown procedure, ordered isolation of feed streams, activated the quench system, and coordinated with the safety team to evacuate the area while monitoring pressure relief valve performance.

The reaction was safely terminated, no injuries occurred, and equipment damage was limited to minor valve wear.