Overview of FE Chemical Engineering
The Chemical Engineering discipline on the FE exam focuses on process engineering fundamentals including mass and energy balances, chemical thermodynamics, transport phenomena, reaction engineering, and process design. Chemical engineering is unique among FE disciplines because it bridges chemistry and engineering, requiring you to apply physical and chemical principles to industrial process problems.
Key Topics
Mass and Energy Balances
Material and energy balances form the foundation of chemical engineering. You must be able to set up and solve steady-state and transient balances on single units and multi-unit processes. Key concepts include degrees of freedom analysis, recycle and bypass streams, reactive systems (extent of reaction, limiting reagent, conversion, selectivity, yield), and energy balances on open and closed systems. Understand how to use the general balance equation: accumulation equals input minus output plus generation minus consumption.
Chemical Thermodynamics
Chemical thermodynamics covers equations of state (ideal gas, van der Waals, Peng-Robinson), phase equilibrium (Raoult's law, Henry's law, activity coefficients, fugacity), chemical equilibrium (equilibrium constant, Le Chatelier's principle, Gibbs free energy minimization), and property estimation. Understand vapor-liquid equilibrium (VLE) diagrams, bubble and dew point calculations, and flash calculations. Know how to use thermodynamic tables and charts from the FE Reference Handbook.
Fluid Dynamics
Fluid dynamics for chemical engineers emphasizes pipe networks, pump sizing, and flow through packed beds and fluidized beds. Key topics include the mechanical energy balance (extended Bernoulli equation), friction factors (Moody chart), equivalent lengths for fittings, NPSH calculations for pump selection, and the Ergun equation for packed bed pressure drop. Understand flow measurement devices (orifice meters, venturi meters) and non-Newtonian fluid behavior.
Heat and Mass Transfer
Heat transfer topics include conduction through composite walls and cylinders, convection correlations, radiation exchange, and heat exchanger design (LMTD and effectiveness-NTU methods). Mass transfer covers Fick's law of diffusion, convective mass transfer coefficients, gas absorption, distillation (McCabe-Thiele method, Fenske equation, Underwood equation), and interphase mass transfer (two-film theory). Understand the analogy between heat and mass transfer (Chilton-Colburn analogy).
Reaction Engineering and Kinetics
Reaction engineering covers rate laws, reactor design equations for batch reactors, CSTRs, and PFRs, conversion calculations, selectivity in multiple reactions, and non-ideal reactor behavior (residence time distribution). Understand the Arrhenius equation, catalytic reaction mechanisms (Langmuir-Hinshelwood kinetics), and how to size reactors for given conversion targets. Know how to compare reactor types for different reaction orders.
Process Design and Safety
Process design topics include process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), process control basics (feedback and feedforward control, PID controllers), and process safety (relief valve sizing, HAZOP, inherently safer design principles). Understand basic economic analysis for process design decisions.
Study Strategy
Mass and energy balances are tested throughout the exam, so become extremely comfortable with balance equations. For thermodynamics, practice VLE calculations and phase diagram interpretation. Reaction engineering problems require careful setup, so practice identifying reactor type and writing the correct design equation. Use FE Exam Prep flashcards for key equations and mini exams for timed practice.