Chemical Engineering project ideas

101 projects, from a first build to a final-year capstone. Each lists the skills it teaches and the tools it needs; times and costs are estimates.

Beginner projects

• Process Mass-Balance Solver — Solve steady-state mass balances for mixers, splitters and separators with recycle streams. Skills: mass balances, recycle, degrees of freedom. Tools: Python/spreadsheet. Simulator, Up to 15 h, Software only (free tools).
• Ideal Gas Law Calculator — Convert between pressure, volume, temperature and moles with unit handling and real-gas warnings. Skills: ideal gas law, units, compressibility. Tools: web calculator. Visualizer, Up to 15 h, Software only (free tools).
• Unit Operations Flowsheet Drawer — Draw a simple process flow diagram with standard symbols and label every stream. Skills: PFD symbols, process flow, documentation. Tools: draw.io/CAD. CAD / design, Up to 15 h, Software only (free tools).
• Viscosity Measurement With Falling Ball — Measure liquid viscosity from terminal velocity of a falling ball and compare with tables. Skills: viscosity, Stokes' law, measurement. Tools: graduated cylinder, ball bearings. Data lab, Up to 15 h, Software only (free tools).
• Solubility Curve Experiment — Measure salt solubility at several temperatures and plot the solubility curve. Skills: solubility, crystallisation basics, plotting. Tools: salts, thermometer, balance. Data lab, Up to 15 h, Under $30.
• Psychrometric Chart Explorer — Read humidity, dew point and enthalpy of air states and plot heating and cooling processes. Skills: psychrometrics, humidity, air conditioning. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Batch Mixing Time Study — Measure mixing time in a stirred beaker with dye at different stirrer speeds. Skills: mixing, impeller speed, residence time. Tools: stirrer, dye, stopwatch. Data lab, Up to 15 h, Software only (free tools).
• pH Titration Curve Plotter — Record titration data and find equivalence points from the curve and its derivative. Skills: titration, pH, equivalence points. Tools: pH meter, burette. Data lab, Up to 15 h, Under $30.
• Stoichiometry and Yield Calculator — Compute limiting reagent, theoretical yield and percent yield for reactions. Skills: stoichiometry, limiting reagent, yield. Tools: web calculator. Visualizer, Up to 15 h, Software only (free tools).
• Heat of Solution Measurement — Measure temperature change when salts dissolve and calculate enthalpy of solution. Skills: calorimetry, enthalpy, energy balances. Tools: coffee-cup calorimeter. Data lab, Up to 15 h, Under $30.
• Vapour Pressure Antoine Calculator — Calculate vapour pressures and boiling points from Antoine constants. Skills: vapour pressure, Antoine equation, boiling points. Tools: web calculator. Visualizer, Up to 15 h, Software only (free tools).
• Filtration Rate Experiment — Measure filtrate volume versus time and estimate cake resistance. Skills: filtration, cake resistance, plotting. Tools: funnel, filter paper, slurry. Data lab, Up to 15 h, Software only (free tools).
• Density and Specific Gravity Lab — Measure densities of liquids with hydrometers and compare with mixture rules. Skills: density, mixtures, measurement. Tools: hydrometer, balance. Data lab, Up to 15 h, Under $30.
• Evaporation Rate Study — Measure evaporation of water under different airflow and temperature. Skills: mass transfer, evaporation, drivers. Tools: trays, fan, balance. Data lab, Up to 15 h, Under $30.
• Reynolds Number Flow Demonstrator — Visualise laminar and turbulent pipe flow with dye and compute Reynolds numbers. Skills: Reynolds number, flow regimes, visualisation. Tools: glass tube, dye. Hardware build, Up to 15 h, Under $30.
• Chemical Hazard Label Reader — Explain GHS pictograms, H/P statements and SDS sections for common chemicals. Skills: GHS, SDS, chemical safety. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Distillation of Water-Ethanol Demo — Distil a dilute ethanol solution and measure product concentration by density. Skills: distillation basics, VLE, measurement. Tools: distillation kit (supervised). Hardware build, Up to 15 h, Under $30.
• Reaction Rate Temperature Study — Measure reaction time at different temperatures and estimate activation energy. Skills: reaction kinetics, Arrhenius, experiments. Tools: reagents, water bath. Data lab, Up to 15 h, Software only (free tools).
• Process Units Converter — Convert flows, pressures and concentrations between process unit systems. Skills: units, conversions, process variables. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Steam Table Lookup Tool — Look up saturated and superheated steam properties with interpolation. Skills: steam tables, interpolation, thermodynamics. Tools: web app. Visualizer, Up to 15 h, Software only (free tools).
• Adsorption of Dye on Charcoal — Measure dye removal by activated charcoal and fit a Langmuir isotherm. Skills: adsorption, isotherms, spectrophotometry. Tools: charcoal, dye, colorimeter. Data lab, Up to 15 h, Under $30.
• Heat Exchanger Concept Model — Build a counter-flow tube heat exchanger model and compare parallel and counter flow. Skills: heat exchange, flow arrangements, temperatures. Tools: copper tube, thermometers. Hardware build, Up to 15 h, Under $30.
• Soap Making Saponification Lab — Make soap and calculate lye quantities from saponification values safely. Skills: saponification, stoichiometry, safety. Tools: lab materials (supervised). Hardware build, Up to 15 h, Under $30.
• Gas Flow Rate Measurement — Measure gas flow with a bubble meter and rotameter and compare. Skills: flow measurement, calibration. Tools: rotameter, bubble meter. Data lab, Up to 15 h, Under $30.
• Material Balance of a Kitchen Recipe — Treat a cooking recipe as a process and track mass and moisture through each step. Skills: mass balances, moisture, process thinking. Tools: kitchen scale. Data lab, Up to 15 h, Under $30.

Intermediate projects

• CSTR Response Simulator — Simulate concentration and temperature response of a CSTR to feed changes and find steady states. Skills: reactor design, dynamics, energy balances. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Distillation Column Calculator — Find minimum reflux and theoretical stages with McCabe-Thiele for binary mixtures. Skills: McCabe-Thiele, reflux, VLE. Tools: Python/web app. Visualizer, 15–45 h, Software only (free tools).
• Batch Reactor Temperature Controller — Control an exothermic batch reactor's temperature with a cooling jacket model and PID. Skills: PID control, exothermic reactions, safety. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• pH Neutralization Control Rig — Control effluent pH with dosing pumps and handle the nonlinear titration curve. Skills: nonlinear control, pH, dosing. Tools: pH probe, pumps, MCU. Hardware build, 15–45 h, $30–150.
• Membrane Separation Model — Model reverse-osmosis flux and rejection versus pressure and concentration. Skills: membranes, osmotic pressure, flux. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Adsorption Breakthrough Simulator — Predict breakthrough curves in a fixed bed with different flow rates. Skills: fixed-bed adsorption, mass transfer zones. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Reaction Kinetics Fitting Workbench — Fit rate laws to concentration-time data and select the best kinetic model. Skills: kinetic modelling, regression, model selection. Tools: Python, SciPy. Data lab, 15–45 h, Software only (free tools).
• Solvent Recovery Estimator — Estimate recoverable solvent and energy cost for distillation-based recovery. Skills: solvent recovery, energy, economics. Tools: spreadsheet/Python. Dashboard, 15–45 h, Software only (free tools).
• Fluidized-Bed Pressure-Drop Model — Predict minimum fluidisation velocity and bed pressure drop and compare with a test rig. Skills: fluidisation, Ergun equation, testing. Tools: Python, test column. Simulator, 15–45 h, Software only (free tools).
• Bioreactor Monitoring Dashboard — Track dissolved oxygen, pH, temperature and growth in a lab bioreactor. Skills: bioprocess monitoring, sensors, dashboards. Tools: sensors, MCU, dashboard. Dashboard, 15–45 h, $30–150.
• Steam Network Efficiency Audit — Audit steam traps, condensate return and insulation losses in a plant. Skills: steam systems, energy audits, losses. Tools: survey tools, spreadsheet. Workflow, 15–45 h, Software only (free tools).
• Chemical Inventory Compatibility Checker — Flag incompatible chemicals stored together and suggest segregation. Skills: chemical compatibility, storage safety, databases. Tools: web app. Workflow, 15–45 h, Software only (free tools).
• Pump Cavitation Monitor — Detect cavitation from NPSH margin and vibration signatures on a pump rig. Skills: NPSH, cavitation, vibration. Tools: pump rig, sensors. Dashboard, 15–45 h, $30–150.
• Batch Recipe Traceability System — Record batch steps, ingredients and deviations with full genealogy. Skills: batch records, traceability, quality. Tools: database app. Workflow, 15–45 h, Software only (free tools).
• Gas Absorption Column Design — Size a packed absorption column with NTU/HTU for removing a gas pollutant. Skills: absorption, packed columns, NTU-HTU. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Heat Transfer in a Jacketed Vessel — Estimate heating time of a jacketed vessel and compare with measurements. Skills: unsteady heat transfer, jackets, U-values. Tools: test vessel, thermocouples. Data lab, 15–45 h, $30–150.
• Liquid-Liquid Extraction Calculator — Compute extraction stages with ternary diagrams for a solute system. Skills: extraction, ternary diagrams, stages. Tools: Python. Visualizer, 15–45 h, Software only (free tools).
• Plug Flow Reactor Model — Compare PFR and CSTR conversions and residence times for various kinetics. Skills: PFR design, conversion, residence time. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Drying Curve Analysis — Measure drying rate periods of a wet solid and identify critical moisture. Skills: drying kinetics, falling rate period. Tools: oven, balance. Data lab, 15–45 h, Software only (free tools).
• Cooling Tower Performance Model — Evaluate cooling tower range, approach and water loss for different loads. Skills: cooling towers, evaporation, psychrometrics. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Corrosion Rate by Weight Loss — Measure corrosion rates of metals in different solutions and rank inhibitors. Skills: corrosion, inhibitors, experimental design. Tools: metal coupons, solutions. Data lab, 15–45 h, Software only (free tools).
• Process Control Loop Tuning Study — Tune level and flow loops using open-loop step tests and Ziegler-Nichols. Skills: loop tuning, step tests, PID. Tools: simulation/rig. Simulator, 15–45 h, $30–150.
• Water Softening Ion-Exchange Model — Model ion-exchange column capacity and regeneration cycles. Skills: ion exchange, capacity, regeneration. Tools: Python. Simulator, 15–45 h, Software only (free tools).
• Particle Size Distribution by Sieving — Sieve a powder sample and compute d50 and size distribution parameters. Skills: PSD, sieving, statistics. Tools: sieves, balance. Data lab, 15–45 h, Software only (free tools).
• Equilibrium Conversion Calculator — Compute equilibrium conversion versus temperature from Gibbs energy data. Skills: chemical equilibrium, Gibbs energy. Tools: Python. Visualizer, 15–45 h, Software only (free tools).
• Effluent Treatment Plant Sizing — Size equalisation, neutralisation and settling units for an effluent stream. Skills: effluent treatment, unit sizing, regulations. Tools: spreadsheet. CAD / design, 15–45 h, Software only (free tools).

Advanced projects

• Heat Exchanger Network Optimizer — Apply pinch analysis to find minimum utilities and design a heat exchanger network. Skills: pinch analysis, HEN design, energy targeting. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Process Hazard Bow-Tie Tool — Build bow-tie diagrams linking causes, barriers and consequences for a hazardous event. Skills: process safety, bow-tie analysis, barriers. Tools: web app. Workflow, 45–100 h, Software only (free tools).
• Crystallization Process Explorer — Model supersaturation, nucleation and growth to predict crystal size distribution. Skills: crystallisation, population balances, kinetics. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Plant Alarm Rationalization Tool — Review alarm lists for priority, setpoints and consequences following alarm-management practice. Skills: alarm management, rationalisation, HMI. Tools: spreadsheet/web app. Workflow, 45–100 h, Software only (free tools).
• Digital Twin of a Mixing Tank — Mirror a mixing tank's level, temperature and concentration in a live model. Skills: digital twins, dynamic models, sensors. Tools: Python, sensor data. Digital twin, 45–100 h, $30–150.
• Waste Minimization Planner — Rank waste reduction options by cost, feasibility and environmental benefit. Skills: waste minimisation, MCDA, cleaner production. Tools: spreadsheet. Workflow, 45–100 h, Software only (free tools).
• HAZOP Worksheet Assistant — Guide a HAZOP study node by node with guide words and record actions. Skills: HAZOP, risk assessment, documentation. Tools: web app. Workflow, 45–100 h, Software only (free tools).
• Reactive Distillation Concept Study — Simulate a reactive distillation column and compare with sequential reactor plus column. Skills: reactive distillation, process intensification. Tools: DWSIM/Python. Simulator, 45–100 h, Software only (free tools).
• Dynamic Simulation of a Flash Drum — Model a flash drum's pressure and level dynamics and design control. Skills: flash separation, dynamics, control. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Fermentation Scale-Up Study — Scale a fermentation from flask to bioreactor using kLa and power-per-volume criteria. Skills: scale-up, mass transfer, bioprocessing. Tools: Python, lab data. Simulator, 45–100 h, Software only (free tools).
• Catalyst Deactivation Model — Model catalyst activity decline and plan regeneration intervals. Skills: catalysis, deactivation kinetics, scheduling. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Process Simulation of an Ammonia Loop — Simulate a simplified ammonia synthesis loop with recycle and purge. Skills: process simulation, recycle, equilibrium. Tools: DWSIM. Simulator, 45–100 h, Software only (free tools).
• Relief Valve Sizing Assistant — Size pressure relief devices for blocked outlet and fire cases. Skills: relief sizing, overpressure scenarios, safety. Tools: spreadsheet. Visualizer, 45–100 h, Software only (free tools).
• Membrane Fouling Prediction — Predict flux decline from fouling and optimise cleaning cycles. Skills: membrane fouling, modelling, optimisation. Tools: Python. Data lab, 45–100 h, Software only (free tools).
• Electrochemical Cell Performance Study — Characterise an electrolytic cell's voltage, efficiency and current density. Skills: electrochemistry, efficiency, polarisation. Tools: power supply, electrodes (supervised). Data lab, 45–100 h, $30–150.
• Process Economics Evaluator — Estimate capital and operating costs and compute NPV and payback for a plant. Skills: cost estimation, NPV, sensitivity. Tools: spreadsheet. Dashboard, 45–100 h, Software only (free tools).
• Polymerization Reactor Model — Model molecular weight distribution in a batch polymerisation. Skills: polymer reaction engineering, MWD. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Dust Explosion Risk Screening — Screen a powder handling area for explosion risk with Kst and MIE data. Skills: dust explosions, risk screening, prevention. Tools: spreadsheet. Workflow, 45–100 h, Software only (free tools).
• Statistical Process Monitoring — Monitor a multivariate process with PCA-based control charts and detect faults. Skills: MSPC, PCA, fault detection. Tools: Python. Data lab, 45–100 h, Software only (free tools).
• Biodiesel Production Optimisation — Optimise transesterification conditions with a designed experiment. Skills: DOE, transesterification, optimisation. Tools: lab setup (supervised), Python. Data lab, 45–100 h, Software only (free tools).
• Extraction of Natural Products — Compare solvent extraction methods for a plant compound and model yield. Skills: extraction, mass transfer, yield modelling. Tools: lab apparatus. Data lab, 45–100 h, Software only (free tools).
• Multi-Effect Evaporator Model — Model steam economy of a multi-effect evaporator train. Skills: evaporation, steam economy, energy balances. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Gas Detection Network Layout — Place gas detectors in a plant area using dispersion scenarios. Skills: gas detection, dispersion, coverage. Tools: Python, GIS. Visualizer, 45–100 h, Software only (free tools).
• Wastewater Anaerobic Digester Model — Model biogas production and stability in an anaerobic digester. Skills: anaerobic digestion, kinetics, biogas. Tools: Python. Simulator, 45–100 h, Software only (free tools).
• Process Control Graphics Mock-Up — Design high-performance HMI screens for a distillation unit. Skills: HMI design, situational awareness, alarms. Tools: HMI tool/web. Visualizer, 45–100 h, Software only (free tools).

Expert projects

• Carbon Capture Process Comparison — Compare amine absorption, adsorption and membranes for CO2 capture by energy and cost. Skills: carbon capture, process comparison, energy penalty. Tools: DWSIM/Python. Simulator, 100 h+, Software only (free tools).
• Process Scale-Up Uncertainty Model — Quantify scale-up risk by propagating kinetic and transport uncertainties. Skills: scale-up, uncertainty quantification, risk. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Flare Minimization Dashboard — Track flaring events, root causes and reduction opportunities across a site. Skills: flare management, emissions, analytics. Tools: dashboard. Dashboard, 100 h+, $150+.
• Exergy Analysis Workbench — Locate where useful energy is destroyed in a process with exergy balances. Skills: exergy, second law, energy efficiency. Tools: Python. Data lab, 100 h+, Software only (free tools).
• Model Predictive Control of a Distillation Column — Control product purities with MPC and compare with decentralised PID. Skills: MPC, multivariable control, distillation. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Green Hydrogen Process Integration — Integrate an electrolyser with downstream ammonia synthesis and evaluate efficiency. Skills: process integration, hydrogen, systems analysis. Tools: DWSIM/Python. Simulator, 100 h+, Software only (free tools).
• Machine Learning Soft Sensor — Predict a hard-to-measure quality variable from routine process data. Skills: soft sensors, ML regression, validation. Tools: Python. Data lab, 100 h+, Software only (free tools).
• Microreactor Process Intensification — Design a microreactor for a fast exothermic reaction and compare safety and yield. Skills: microreactors, heat transfer, intensification. Tools: CFD/Python. Simulator, 100 h+, Software only (free tools).
• Plastic Waste Pyrolysis Model — Model pyrolysis product yields from plastic feed and evaluate energy balance. Skills: pyrolysis, kinetics, recycling. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Dynamic Safety Barrier Monitor — Track barrier health in real time and update risk levels from live data. Skills: barrier management, dynamic risk, monitoring. Tools: dashboard. Dashboard, 100 h+, $150+.
• Supply-Chain Optimisation for Chemicals — Optimise production and transport across plants under demand uncertainty. Skills: supply chain, MILP, uncertainty. Tools: Python, solvers. Simulator, 100 h+, Software only (free tools).
• Computational Fluid Dynamics of a Stirred Tank — Simulate flow patterns and mixing time for different impellers. Skills: CFD, mixing, impeller design. Tools: OpenFOAM. Simulator, 100 h+, Software only (free tools).
• Electrochemical CO2 Reduction Study — Model and test product selectivity of CO2 electroreduction. Skills: electrocatalysis, selectivity, kinetics. Tools: lab cell (supervised), Python. Data lab, 100 h+, Software only (free tools).
• Real-Time Optimisation of a Plant — Update steady-state setpoints from live data to maximise profit. Skills: RTO, model updating, economics. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Molecular Simulation of Adsorbents — Screen porous materials for gas adsorption with molecular simulation. Skills: molecular simulation, GCMC, materials screening. Tools: RASPA-style tools. Simulator, 100 h+, Software only (free tools).
• Bioprocess Digital Twin — Build a hybrid mechanistic-ML twin of a fed-batch bioreactor. Skills: hybrid modelling, bioprocesses, digital twins. Tools: Python. Digital twin, 100 h+, Software only (free tools).
• Fault Tree Analysis of a Reactor System — Build fault trees for a runaway scenario and compute top-event probability. Skills: FTA, reliability, quantitative risk. Tools: Python/web app. Workflow, 100 h+, Software only (free tools).
• Solar-Driven Desalination Concept — Model a solar-thermal desalination unit and estimate water cost. Skills: desalination, solar thermal, techno-economics. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Life-Cycle Assessment of a Solvent — Compare environmental impacts of conventional and green solvents. Skills: LCA, green chemistry, impact categories. Tools: LCA tool. Data lab, 100 h+, Software only (free tools).
• Self-Optimising Flow Chemistry Rig — Use Bayesian optimisation to adjust a flow reactor's conditions automatically. Skills: autonomous experimentation, Bayesian optimisation. Tools: flow reactor, Python. Hardware build, 100 h+, $150+.
• Corrosion Under Insulation Risk Model — Prioritise pipe inspection by modelling CUI likelihood and consequence. Skills: risk-based inspection, corrosion, prioritisation. Tools: spreadsheet/Python. Data lab, 100 h+, Software only (free tools).
• Process Mining of Batch Deviations — Mine event logs of batches to find deviation patterns and root causes. Skills: process mining, deviations, root cause. Tools: Python, pm4py. Data lab, 100 h+, Software only (free tools).
• Electrified Process Heating Study — Compare electric heating options to replace fired heaters and estimate emissions savings. Skills: electrification, heat integration, decarbonisation. Tools: Python. Simulator, 100 h+, Software only (free tools).
• Sustainable Biorefinery Design — Design a biorefinery producing several products from biomass and assess economics. Skills: biorefining, process design, techno-economics. Tools: DWSIM, spreadsheet. Simulator, 100 h+, Software only (free tools).
• Inherent Safety Index Calculator — Score process routes on inherent safety and choose the safer alternative. Skills: inherent safety, indices, route selection. Tools: spreadsheet. Workflow, 100 h+, Software only (free tools).

Project ideas for every branch · Chemical Engineering roadmap