My STEP Signature Project was a process/production engineering internship with major chemicals and plastics manufacturer LyondellBasell at its Channelview Complex in Houston, Texas. I worked on high-impact projects, the main ones being to optimize throughput within our liquid hydrocarbons reaction and separation unit and improve emissions and energy and cost efficiency of other related processes within the plant. Learning and refining various technical skills and navigating a layered and diverse company structure, I had a well-rounded internship experience and emerged with a much deeper and broader perspective into networking, engineering in industry, and my own career path.
This internship transformed my understanding of my professional and technical knowledge very significantly. Students form various pictures of industry and the professional world before they are able to work their first technical job through stories from their friends and family, lectures and talks with industry representatives, and even their textbooks. I learned upon working in the field during this internship, my own first experience in a technical engineering role, that my pre-conceived notions about chemical engineering and industry formed during my time in class were very different from what is really the case. I began to understand that at the level of education I want to complete in engineering, the average chemical engineer will not get much use out of a large portion of the curriculum we are taught in class. Much of modern industry has access to software that will complete many of the calculations we are taught in our core classes faster and more reliably than if they were done by hand, and that software can simulate systems that humans could never hope to match by hand. What is important is an understanding of the system and the knowledge to apply the correct ideology to each problem in the industry because that is the part of the battle that technology can’t figure out by itself just yet.
Working as a process/production engineer in the petrochemicals industry also brought my personal career aspirations into much closer focus. Process engineering is a shining example of what a chemical engineer can do in industry, and I very much enjoyed understanding and solving the problems associated with the hydrocarbons and other interrelated utilities and side streams that helped my unit produce a synthetic rubber for applications like car tires and helped the whole plant produce the building blocks for plastics and other products. I also learned that there are many ways to make a great impact on a company; I spoke and networked with people who worked in higher technical and managerial roles as well as business roles like finance, procurement, and operations and began to hear about the many opportunities for students with engineering degrees to branch out and explore other roles and career paths using an engineering mindset in a company. Working in industry and getting the opportunity to hear about these roles and paths, I was able to discover so much about my passion for my future and transform my view of industry.
A few of the many experiences I had during my internship stand out to me as very transformational to my professional and personal life. One of these was a tower “clean” inspection we did during a turnaround of one of Channelview’s units. A turnaround happens every few years when a unit which is usually running continuously shut down entirely in order to perform invasive maintenance that cannot be performed when the unit is running, and one of these maintenance items is to clean the towers on the line to rid the towers of debris and contaminants; my mentor and another production engineer were tasked with inspecting one cleaned tower to make sure everything was clean and there were no structural issues, and they invited me along to climb the tower with them. Climbing the tower involved entering the tower itself (a large metal tube with various stages to promote mixing as liquids inside move through) and climbing several stories upwards through a space that usually held dangerous chemicals. The operation took several stages of verification and several plant workers to oversee, and all of the confined space and fall hazard training we did in the beginning of the year was put to the test in order to complete this very important piece of the effort to get the tower back up and running. I came away from that climb with a great appreciation for those who do those climbs daily, and the safety measures required to make it all possible gained a new meaning to me. In an industry where process safety and personal safety mistakes could be harmful or fatal, it transformed my understanding of the importance of safety after practicing it firsthand in a dangerous situation.
One of my major projects reformed my vision of green engineering as well. The part of Channelview that my team oversaw was called East Plant and had four different units, all of which received their process feedstocks and some utilities from the olefins furnaces in a different part of Channelview. East Plant’s flare, where material not used by the plant is sent to combust and escape into the atmosphere, was having problems completely combusting that material and required more fuel gas to make the flame at the flare tip hotter so that the material would be fully converted into less harmful emissions. Methane was used before my term because it was on hand, but burning methane increased the carbon monoxide emissions from the plant, so the plant was looking for a different fuel source for the flare. My mentor and I came up with a plan to take product hydrogen from the olefins furnaces and send it to burn in the flare, which simultaneously served as an economical advantage from freeing up storage limitations from the furnaces and an environmental advantage from burning a cleaner fuel. This project really opened my eyes to the capability for manufacturing processes to improve their environmental footprint by taking advantage of energy, process, and utility integration. I never knew that making a large, sweeping impact could be relatively easy to enact given the right setup and knowledge of the system. I came to Ohio State passionate about using my chemical engineering knowledge to make a positive impact on the environment, and LyondellBasell gave me the capability to do that in Houston and will ensure that the changes I offered will be put into place and continue to make an impact for years to come. This internship strengthened my passion to use green/lean engineering methods to approach emissions reduction by putting me on the front lines of the issue in a manufacturing setting where I could make some of the highest impact on the issues facing the environment.
My internship with LyondellBasell has influenced me to refocus my academic path for the rest of my time at OSU. I want to take classes that focus on green engineering, and the chemical engineering curriculum includes technical electives such as Principles of Sustainable Engineering and Air Pollution that would help me learn about the engineering methods that could make me a better candidate for positions in industry that are geared toward green engineering and environmental work. I also want to foray a bit into management or other business electives that could help me understand principles for better employee management. I really enjoyed experiencing that side of the business during my internship and believe I would like to make team management a part of my career. The internship also gave me unique management experience that I will be able to take back to my student organization in which I have been elected president for the upcoming year. I haven’t yet had the opportunity to have this much responsibility leading a team, and I think the internship experience I bring back to college will be very impactful in guiding my team of board and general body members through a simultaneously uncertain and busy time.
I feel that this STEP Signature Project internship is my crucial starting point into a bright career path. With my foot finally in the industry door, I can approach new professional opportunities with confidence and technical knowledge that will help me chase what’s best for my career moving forward. My transformed and reinvigorated passions can guide me onto a path I will be very happy with professionally and personally. The technical, professional, and personal experience I have gained will be invaluable in both my academic and my extracurricular future at college, and it will help shape my life well into the future. I’m excited to dive into this new chapter of college with what I’ve learned from my STEP Signature Project!
Matthew Greenwaldt