Process Integration Concepts Research Articles

The integration of biomass torrefaction with coal gasification: Performance study and process simulation

Conventional biomass torrefaction process in a N2 atmosphere presents economic and environmental challenges, including the necessity for N2 separation from air, additional fuel consumption for heat supply, and the post-treatment of low-calorific gaseous by-products. Hence, the concept of process integration, which includes heat integration and the effective utilization of by-products, is highly desirable. This study proposed a novel concept of integrating biomass torrefaction with coal gasification to achieve both heat integration and the co-processing of gaseous by-products from biomass torrefaction and raw syngas (RS) from coal gasification. To this end, torrefaction tests were comparatively conducted on pine sawdust (PS) in a simulated RS atmosphere and its mono- or bi-component atmosphere at 280 and 320 °C. The results revealed that a marked improvement in the grindability and energy densification of the solid products when torrefaction was performed in the RS atmosphere compared with the N2 atmosphere. This improvement in the RS atmosphere was attributed to the promoting effects of the CO2 and H2O components in RS on the degradation of PS during torrefaction. The process simulation results indicated that, when utilizing RS at 600 °C as a heat carrier, the gas-solid feed ratios of 0.36 and 1.18 Nm3 kg-1 were required to achieve the torrefaction of PS at 280 and 320 °C, respectively. These findings offer valuable insights into the potential integration of biomass torrefaction with coal gasification.

Concept of an Enzymatic Reactive Extraction Centrifuge

Biocatalytic processes often provide an ecological alternative to many chemical processes. However, further improvements in terms of the economic efficiency are required. In order to achieve that, the concept of process integration is a promising option. Applying this within a biocatalytic process, a highly integrated apparatus working as a reactive extraction centrifuge was developed and operated. For this purpose, a commercially available extraction centrifuge was modified to implement a biocatalytic reaction. The novel apparatus was used within a multi-enzyme cascade for the production of a natural flavor and fragrance, namely cinnamic ester. The characterization of the reactive extraction centrifuge and the suitable operation conditions for the inlet streams and the rotational speed for a stable operation were determined. Furthermore, different initial substrate concentrations were applied to prove the reaction. The results provide a successful proof of concept for the novel reactive extraction centrifuge.

Methodology for design of vapor permeation membrane-assisted distillation processes for aqueous azeotrope dehydration

Membrane-assisted distillation (MAD) is a classic process-integration concept applied for an aqueous azeotrope dehydration. An engineer needs to decide what is the best balance point to trade-off the energy consumption of distillation and the capital cost of membrane module. The current study proposes a design methodology for optimizing the balance point of vapor permeation (VP) membrane-assisted distillation processes. As a generic case, thermodynamically non-ideal process of ethanol dehydration is used to obtain the design information that provides broad insights into the MAD operation. Furthermore, the proposed method provides a reasonable estimation of the concentration and pressure of the connection stream between membrane separation and distillation (which are the most important parameters in the VP-MAD integration process) based on the total annual cost (TAC) calculation in ACM®. Successful application of the methodology is demonstrated for the dehydration of ethanol with different target product grades (99.6 wt% and 99.95 wt%) that need different hybrid configurations.

Process integration concept for waste reduction among manufacturing planning, modularization and validation

Waste reduction for assembly products is essential for Circular Economy in not only European Unions but also all over the world. It is also known that recycling contributes to the waste reduction. In order to build the recycling process in a product lifecycle effectively and efficiently, a process integration should be required among manufacturing planning, modularity design and multivariate process validation. This study proposes a process integration concept for the waste reduction among the manufacturing planning, modularization and validation.

Problem-based learning of process systems engineering and process integration concepts with metacognitive strategies: The case of P-graphs for polygeneration systems

Problem-based Learning (PBL) is regarded by many education experts as superior to the traditional lecture, particularly for learning higher-order skills and concepts. PBL can be further reinforced through the utilization of metacognitive skills on the part of the students. Such approaches are particularly useful in Process Systems Engineering (PSE) and Process Integration (PI), where proficiency in the use of methodologies for problem-solving is paramount. In this paper, we describe how such educational strategies can be used to improve learning outcomes through the use of the process graph (P-graph) framework for the synthesis of polygeneration systems, in addition to conventional approaches using lectures and drills. Practical pedagogic implications are then discussed for potential use in teaching related topics in PSE/PI.

Energy benchmarking of cement industry, based on Process Integration concepts

Cement industry is considered as an energy intensive industry, owing to the huge amount of heat consumed in pyro-process unit. There are many conventional methods around, which can be applied to carry out energy targeting in a cement production plant, including conceptual, mathematical or even hybrid. However, full application of these approaches would be time-consuming and costly. So, in this research, our attempt has been focused on development of a rapid approach for benchmarking of an existing plant with respect to energy consumption, and subsequently estimating an achievable scope for energy saving. To realize this goal, five different pyro-process units were simulated and then targeted using Pinch Analysis approach. Having done this conceptual analysis, the obtained results were mathematically correlated to shape a benchmarking model. The resulting model was also validated, in terms of accuracy, and was applied to other cement plants and showed an energy saving potential of up to 24%.

Benchmarking of olefin plant cold-end for shaft work consumption, using process integration concepts

The olefin plant is all about separating cracked gas into ethylene, propylene and other heavier by-products using low-temperature gas separation processes. This process is energy-intensive and hence retrofitting for energy saving would be desirable. However, a full retrofit study requires a lot of time and costly engineering work. So, a novel method is introduced in this paper for benchmarking of shaft work consumption in olefin cold-end, which is based on process integration concepts. In developing this method, the amount of shaft work required in refrigeration cycles was first targeted via application of Pinch Analysis to six different olefin plants followed by the calculation of feasible and achievable energy saving potential. When doing so, the effect of predominant factors such as plant capacity, feedstock (naphtha or natural gas), products specification and type of technology being used was investigated as well. Finally, a mathematical model was developed for rapid estimation of energy saving potential using the above key factors. This model was verified through case studies and was proved to be accurate enough for shortcut calculations.

Anaerobic digestion of monocotyledons in particleboard production – a concept of process integration to increase substitution of wood raw material

The purpose of this conceptual study was to introduce a possibility of integrating a surface treatment of monocotyledons by enzymes into particleboard production to provide a substitute raw material to replace wood particles. Because of the greater competition for wood as a raw material for particleboard production, there is increasing interest in monocotyledons as a substitute for wood. Monocotyledons, such as grass or cereal straw, differ from wood mostly in that they have a surface layer of waxes and embedded silica. If particles of monocotyledons are to be used in combination with wood in particleboards they must be modified. Using the concept of anaerobic digestion, it is possible to modify the surface of monocotyledon particles, having methane as a side product and to achieve a process, which leads to greater product diversity. A SWOT analysis was used to evaluate the process.

Process analysis of a low emissions hydrogen and steam generation technology for oil sands operations

A conceptually simple and powerful method to reduce CO2 emissions from Alberta oil sands operations by decarbonizing natural gas (NG) fuel prior to combustion is proposed, thus removing carbon from the process up front. The natural gas decarbonization (NGD) process can be integrated with either in situ bitumen recovery or upgrading processes or both. The process generates hydrogen and carbon black, a stable marketable form of carbon. Decarbonizing the NG fuel to hydrogen reduces downstream CO2 emissions and obviates the requirement for CO2 sequestration since the carbon is stored in a solid form. The hydrogen can be used as either a fuel for steam generation or for hydrotreating. In addition, steam is generated from the hydrogen combustion reaction itself. A near-zero emissions process is achievable by using the hydrogen generated as the fuel for decarbonization. We used process modeling to assess the performance of hydrogen production and steam generation using two major process integration concepts: (i) Oxy-NG combustion integrated with the NGD process and (ii) Substantially zero emissions concept via an autothermal process using hydrogen product as the energy source for the process NGD process. Though energy penalties are incurred in the decarbonization process, we identify several potential practical process options. The proposed technology is particularly suitable for heavy oil recovery and upgrading, and fuel combustion for power generation.

The Impact of Information System-Enabled Supply Chain Process Integration on Business Performance: A Resource-Based Analysis

This paper seeks to develop and test a model to examine the relationships between, technical aspects of IS resources (IS alignment, IS resources technical quality, IS advancement), supply chain process integration, and firm performance. A questionnaire-based survey was conducted to collect data from 227 supply chain, logistics, or procurement/purchasing managers of leading manufacturing and retail organizations. Drawing on resources-based view of the firm, and through extending the concept of process integration in supply network, as well as broadening the scope of role of IS resources in relation to process integration and performance gain from the focal firm to the entire supply chain, we found that supply chain process integration is an important multidimensional intermediate organizational capability through which the value of IS resources for supply chain management can be materialized. This capability serves as a catalyst in transforming the value of technical aspects of IS resources into higher performance gain for a firm. Thus, the importance of formation of all dimensions of this capability across supply network should be realized. Moreover, the result suggests that the technical aspects of IS resources need to be jointly developed by supply partners to effectively form supply chain capabilities.

Forecast competitor service strategy with service taxonomy and CI data

PurposeThe paper aims to develop a service taxonomy model and a mathematical process to forecast a competitor's service business strategy in a multiple service business context by inputting CI data such as the profits of existing core services.Design/methodology/approachA qualitative method of literature review is adopted to build a service taxonomy model and form two propositions. Based on the multiple business process integration concept of the resource‐based view, a mathematical process constituted by service modules and weights is developed. Salient components of the competitor's service business are identified to forecast the competitor's service business strategy after utilizing optimization heuristics of 80/20 and large number rules.FindingsThe model is able not only to forecast a competitor's service business strategy, but can also help develop the firm's own new service strategy. The resources of the firm can then be realigned to counteract the competitor's strategy.Research limitations/implicationsThe developed model is mainly applicable to service businesses. The collection and use of CI data must consider ethical issues, which might limit the sources of data.Practical implicationsTo forecast a competitor's strategy correctly , good quality CI practice is necessary. Experienced people in the CI department are critical to the production of good quality forecasts.Originality/valueThe contribution to CI impact studies is that the mathematical forecasting process is developed based on qualitative service taxonomical research. Key elements of the service process are identified as salient elements, which serve as the main focusing points in forecasting competitors' strategy.

The Internet and the Deconstruction of the Integrated Banking Model

The rapid development of information and communication technologies (ICTs), with the Internet being one of the most significant, is shaking the foundation of the banking industry. Simply deploying the Internet as a more efficient distribution channel will not bring sustainable strategic advantages. To compete effectively, banks may need to embrace a new set of strategic priorities, based on the ‘unbundling’ of banking services and processes, and the ‘deconstruction’ of the integrated banking model. Such a radical transformation threatens the profitability and survival of some existing incumbent banks, and at the same time, it brings a cohort of new opportunities and powerful new players to the market. This paper reviews existing studies on the use of the Internet in banking, and highlights two prevailing models and the strategic thinking behind them. Based upon recent empirical evidence gathered from in‐depth case studies and other information sources in the UK, the paper discusses a number of emerging tendencies and explores possibilities to reconcile the discrepancies between the two prevailing models. The paper calls for a radical departure from existing strategies in the banking industry based on the concept of process integration and service bundling. A new framework is outlined for banks and other financial organizations in developing and evaluating their strategies. The latest evidence suggests that at least eight models of Internet banking, somewhere on the spectrum between the two prevailing models highlighted by previous studies, have emerged in the UK. These models are illustrated briefly in the paper. This is still a rapidly evolving area, and new research is clearly needed to understand the key dynamics of the banking industry in the networked economy. Finally, some themes for further research are highlighted.

Prospects for integrated management and control of total sites in the batch manufacturing industry

A number of production control concepts for the discrete manufacturing and assembly industries have been developed and also extended to the chemical process industries. However some of the basic aspects of batch processes are not adequately handled by standard commercial software. In this work a summary is made of industrial requirements. Then, we focus in the underlying philosophy of our present solution approach. Three main areas of improvement in the management of batch processes are described: realistic and detailed representation of plant operations, appropriate decision-making structures allowing for the design, analysis, validation and scheduling, monitoring and control of plant operation strategies, and process integration concepts. An illustrative example will be used to show the progress made and future direction of our work is indicated.

Process integration concept

The integration of competitive VLSI technologies to obtain new processes and products requires in turn the availability on the same environment of data and computer-based tools at present scattered among development and manufacturing departments. The need for tools integration involving CAD and CAM functions is the subject of this work. The manufacturing and development environments are described and then an overview of the existing tools for integrate their functionalities is given.