Downloads

Download as Word Document (DOCX)

Case Study: Using DALL-E for Visual Learning in Chemical Engineering

Course Context

Course: Chemical Process Safety (ChE 4185)
Level: Senior
Enrollment: 42 students
Prior Format: Lecture-based with case studies and hazard analysis exercises
Tools: Process simulation software, hazard analysis templates
Faculty: Dr. P, Associate Professor of Chemical Engineering

Implementation Challenge

Dr. P identified several challenges in her chemical process safety course that AI-generated imagery could potentially address:

Hazard Visualization: Difficulty helping students visualize complex hazard scenarios
Industrial Context: Limited exposure to diverse chemical plant environments
Safety Concept Abstraction: Students struggling to grasp abstract safety concepts
Risk Communication: Need for effective visual communication of safety information
Engagement with Technical Content: Traditional textbook illustrations not engaging modern students

Implementation Goals

The integration of DALL-E (OpenAI's image generation AI) aimed to:

Create customized visual learning materials for chemical process safety
Help students visualize hazard scenarios in diverse industrial contexts
Develop students' ability to communicate safety concepts visually
Enhance engagement with technical safety content
Teach critical evaluation of AI-generated technical imagery

Implementation Process

Phase 1: Faculty Preparation (2 months before semester)

Tool Exploration:
- Experimented with DALL-E 3 through ChatGPT Plus
- Developed effective prompting strategies for chemical engineering imagery
- Tested accuracy limitations for technical processes and equipment
- Cataloged successful approaches for different safety concepts
- Created evaluation framework for technical accuracy
Content Development:
- Created image series for high-priority safety concepts
- Developed before/after hazard scenario visuals
- Generated comparative imagery of safety systems across industries
- Created visual decision trees for emergency response
- Designed visual aids for hazard and operability studies (HAZOP)
Integration Planning:
- Identified specific lectures for enhanced visual content
- Developed student activities using AI-generated imagery
- Created assessment approach for visual safety communication
- Designed prompt engineering guidelines for chemical engineering contexts
- Established ethical guidelines for AI image generation and use

Phase 2: Initial Implementation (First three weeks)

Introduction to Visual Safety Communication:
- Demonstrated the power of visual communication in process safety
- Introduced AI-generated imagery as a safety communication tool
- Discussed limitations and ethical considerations
- Showed examples of accurate vs. misleading technical imagery
- Explained evaluation criteria for technical visuals
Guided Exploration Activity:
- Students analyzed pre-generated safety scenario images
- Small groups identified hazards visible in the imagery
- Comparative analysis of traditional diagrams vs. AI-generated visuals
- Discussion of how visual elements communicate risk
- Practice evaluating technical accuracy of process equipment depictions
Prompt Engineering Workshop:
- Taught specialized prompting techniques for chemical process equipment
- Conducted step-by-step demonstration of iterative prompt refinement
- Provided chemical engineering-specific terminology guidance
- Practiced creating technically accurate prompts in small groups
- Discussed limitations and verification requirements

Phase 3: Progressive Integration (Throughout semester)

Visual Case Study Enhancement:
- Traditional case studies supplemented with AI-generated scenario visuals
- Students compared textual descriptions with visual representations
- Discussions about what visuals reveal that text alone might miss
- Analysis of how visual elements influence risk perception
- Practice identifying safety systems and failures in visual scenarios
Student-Generated Visual Communications:
- Students created their own DALL-E prompts for assigned safety scenarios
- Iterative refinement based on technical accuracy feedback
- Peer review of imagery for engineering accuracy and safety communication
- Development of multi-image sequences showing accident progression
- Creation of visual safety briefings for specific chemical processes
Integration with Hazard Analysis:
- HAZOP studies enhanced with visual representations of deviation scenarios
- Layer of Protection Analysis (LOPA) diagrams generated to show safeguards
- Fault tree analysis visually enhanced with AI-generated imagery
- Emergency response scenarios visualized for training discussions
- Comparison of AI-visualized vs. traditional hazard communication approaches

Implementation Examples

Example 1: From Text to Visual - Hazard Scenario Visualization

Traditional Approach: Students read textual case study descriptions and tried to mentally visualize complex accident scenarios.

DALL-E-Enhanced Approach: Dr. P created a progression of images showing the development of a runaway reaction scenario in a batch reactor, with each stage visualized to help students understand the sequence of events.

Example Prompt Evolution:

Initial Prompt:
"Chemical reactor explosion"

Refined Prompt:
"A sequence showing the stages of a runaway reaction in a jacketed batch reactor in a chemical plant. Start with normal operation, then show signs of cooling system failure, pressure buildup, relief valve activation, and finally containment failure with reactive material release. Show proper industrial setting with realistic equipment, operators, and safety systems. Chemical engineering technical accuracy is essential."

Learning Application: Students analyzed the visual sequence to:

Identify early warning signs visible in the imagery
Note which safety systems were present/absent
Discuss how the scenario might differ with additional safeguards
Connect visual cues to process safety concepts
Develop their own narrative explaining the incident causes

Example 2: Visual Safety Communication Project

Assignment Description:

For your mid-term project, you will develop a visual safety communication package for the assigned chemical process. Using DALL-E, create a series of 5-7 images that effectively communicate:

The normal operating conditions and key process equipment

Critical potential hazards specific to this process

Proper safety systems and protective measures

Emergency response procedures

Lessons from a historical incident involving this process

For each image, document your prompt engineering process, including initial prompts, refinements, and technical accuracy evaluations. Prepare a 10-minute presentation explaining how your visual package communicates essential safety information.

Student Workflow:

Research assigned chemical process and historical incidents
Draft initial prompts focusing on technical accuracy
Generate and evaluate preliminary images
Refine prompts based on feedback and technical review
Evaluate final imagery for engineering accuracy
Develop accompanying explanatory text
Present visual safety package to class

Evaluation Rubric Excerpt:

Technical accuracy of chemical equipment and processes (30%)
Effectiveness in communicating safety concepts visually (25%)
Quality of prompt engineering and refinement process (20%)
Critical evaluation of AI-generated imagery limitations (15%)
Integration with process safety principles (10%)

Example 3: Comparative Hazard Analysis

Traditional Approach: Students completed HAZOP worksheets using text descriptions and generic process diagrams.

DALL-E-Enhanced Approach: Students generated visuals of normal operations and deviation scenarios for each HAZOP node, creating a visual HAZOP that showed the consequences of different process deviations.

Comparative Analysis Assignment:

For your assigned distillation process:

Complete the standard HAZOP worksheet using the template provided

For each identified deviation with serious consequences, use DALL-E to create a visual representation showing:

The normal operation condition

The deviation scenario with visible consequences

The safety systems that would mitigate the hazard

Evaluate which approach (traditional HAZOP or visual HAZOP):

Better identifies potential hazards

More effectively communicates risk to operators

Would be more useful in safety training

Has limitations in technical accuracy

Recommend a best-practice approach that combines traditional and visual elements

Assessment and Evaluation

New Assessment Approaches

Visual Hazard Identification Quizzes:
- AI-generated scenarios with multiple hazards to identify
- Students mark and explain each identified hazard
- Technical accuracy evaluations of visual safety elements
- Comparison with traditional text-based hazard identification
Prompt Engineering Quality Assessment:
- Evaluation of students' ability to create technically accurate prompts
- Documentation of refinement process
- Critical analysis of generated imagery
- Technical accuracy verification strategies
Visual Safety Communication Portfolio:
- Collection of student-created safety visualizations
- Reflection on effectiveness for different audiences
- Connection to process safety management principles
- Evaluation of technical communication abilities

Evaluation Framework for AI-Generated Technical Content

Dr. P developed a specific rubric for evaluating the quality of AI-generated chemical engineering imagery:

Equipment Accuracy: Correct representation of process equipment features
Process Fidelity: Accurate depiction of chemical processes and flows
Safety System Representation: Correct safety elements shown
Scale and Proportion: Realistic size relationships between components
Environmental Context: Appropriate industrial setting and conditions
Human Factors: Realistic operator interactions and PPE
Technical Limitations: Awareness of inaccuracies and their implications

Potential Outcomes and Considerations

Expected Benefits

Enhanced ability to visualize complex hazard scenarios
Improved engagement with technical safety content
Better understanding of spatial relationships in process equipment
Improved ability to identify potential hazards from visual cues
More effective communication of safety concepts
Development of visual literacy for technical contexts
Bridging of knowledge gap for students without plant experience

Potential Challenges

Technical inaccuracies in AI-generated imagery requiring verification
Time investment needed to develop effective prompts
Risk of reinforcing misconceptions through visuals if not properly vetted
Need for consistent verification of technical accuracy
Balancing visualization benefits with traditional analytical methods
Risk of student over-reliance on visual vs. analytical approaches

Faculty Implementation Considerations

Key Implementation Strategies

Progressive skill development in both safety analysis and prompt engineering
Comparative approaches showing traditional and visual methods together
Integration with existing frameworks like HAZOP and LOPA
Critical evaluation emphasis preventing over-reliance on AI visuals
Scenario-based learning enhanced through visual progression

Important Considerations

Technical accuracy verification must be explicitly taught and emphasized
Domain-specific prompt libraries save significant time and improve consistency
Visual literacy is a distinct skill requiring dedicated development
Balance of visual and analytical approaches prevents over-reliance on either
Misconceptions can be reinforced if visuals aren't critically evaluated

Future Refinement Directions

If implementing such an approach, consider:

Developing a comprehensive chemical engineering prompt library
Creating a technical accuracy checklist specific to different process equipment
Implementing structured comparison between AI visuals and real plant images
Adding more quantitative analysis to complement visual hazard identification
Developing advanced prompt engineering training for technical accuracy

Resources Developed

Chemical Engineering Prompt Library: Equipment and process-specific prompts
Technical Accuracy Checklist: Verification guide for different equipment types
Visual HAZOP Template: Framework integrating visuals with traditional HAZOP
Safety Visualization Rubric: Assessment criteria for visual safety communication
Chemical Process Imagery Database: Categorized collection of verified visuals

Implementation Advice

For Faculty Considering Similar Integration:

Start with comparative approaches that combine traditional and visual methods
Emphasize technical verification from the beginning
Build a discipline-specific prompt library progressively
Integrate with existing frameworks familiar to students
Teach prompt engineering as a distinct technical communication skill

Technical Considerations:

DALL-E currently struggles with: Internal equipment details, proper scale relationships, some technical accuracy
Strengths include: Environmental context, general arrangement, hazard visualization, engagement factor
Always verify generated imagery against technical references
Iterative prompting is essential for technical accuracy
Documentation of limitations should be explicitly included in student work

This case study was developed as part of the "Strategies for Integrating Generative AI in Engineering Education" workshop materials in collaboration with Claude-3.7 Sonnet.

Using DALL-E in a Chemical Engineering Process Design Course