Industrial chemistry and manufacturing technologies Books

Book SynopsisExploring methods and techniques to optimize processing energy efficiency in process plants, Energy Optimization for the Process Industries provides a holistic approach that considers changing process conditions, process design changes, and upgrading process technology that has already been used in a process plant with success.Table of ContentsPREFACE xv PART 1 BASIC CONCEPTS AND THEORY 1 1 Overview of this Book 3 1.1 Introduction, 3 1.2 Who is this Book Written for?, 4 1.3 Five Ways to Improve Energy Efficiency, 5 1.4 Four Key Elements for Continuous Improvement, 7 1.5 Promoting Improvement Ideas in the Organization, 8 2 Theory of Energy Intensity 9 2.1 Introduction, 9 2.2 Definition of Process Energy Intensity, 10 2.3 The Concept of Fuel Equivalent (FE), 11 2.4 Energy Intensity for a Total Site, 13 2.5 Concluding Remarks, 15 3 Benchmarking Energy Intensity 16 3.1 Introduction, 16 3.2 Data Extraction from Historian, 17 3.3 Convert All Energy Usage to Fuel Equivalent, 17 3.4 Energy Balance, 21 3.5 Fuel Equivalent for Steam and Power, 23 3.6 Energy Performance Index (EPI) Method, 29 3.7 Concluding Remarks, 32 4 Key Indicators and Targets 35 4.1 Introduction, 35 4.2 Key Indicators Represent Operation Opportunities, 36 4.3 Define Key Indicators, 39 4.4 Set up Targets for Key Indicators, 45 4.5 Economic Evaluation for Key Indicators, 49 4.6 Application 1: Implementing Key Indicators into an "Energy Dashboard," 53 4.7 Application 2: Implementing Key Indicators to Controllers, 56 4.8 It is Worth the Effort, 57 PART 2 ENERGY SYSTEM ASSESSMENT METHODS 59 5 Fired Heater Assessment 61 5.1 Introduction, 61 5.2 Fired Heater Design for High Reliability, 62 5.3 Fired Heater Operation for High Reliability, 68 5.4 Efficient Fired Heater Operation, 73 5.5 Fired Heater Revamp, 80 6 Heat Exchanger Performance Assessment 82 6.1 Introduction, 82 6.2 Basic Concepts and Calculations, 83 6.3 Understand Performance Criterion—U Values, 89 6.4 Understanding Pressure Drop, 94 6.5 Heat Exchanger Rating Assessment, 96 6.6 Improving Heat Exchanger Performance, 106 7 Heat Exchanger Fouling Assessment 112 7.1 Introduction, 112 7.2 Fouling Mechanisms, 113 7.3 Fouling Mitigation, 114 7.4 Fouling Mitigation for Crude Preheat Train, 117 7.5 Fouling Resistance Calculations, 119 7.6 A Cost-Based Model for Clean Cycle Optimization, 121 7.7 Revised Model for Clean Cycle Optimization, 125 7.8 A Practical Method for Clean Cycle Optimization, 128 7.9 Putting All Together—A Practical Example of Fouling Mitigation, 130 8 Energy Loss Assessment 138 8.1 Introduction, 138 8.2 Energy Loss Audit, 139 8.3 Energy Loss Audit Results, 147 8.4 Energy Loss Evaluation, 149 8.5 Brainstorming, 150 8.6 Energy Audit Report, 152 9 Process Heat Recovery Targeting Assessment 154 9.1 Introduction, 154 9.2 Data Extraction, 155 9.3 Composite Curves, 156 9.4 Basic Concepts, 159 9.5 Energy Targeting, 160 9.6 Pinch Golden Rules, 160 9.7 Cost Targeting: Determine Optimal DTmin, 162 9.8 Case Study, 165 9.9 Avoid Suboptimal Solutions, 169 9.10 Integrated Cost Targeting and Process Design, 171 9.11 Challenges for Applying the Systematic Design Approach, 172 10 Process Heat Recovery Modification Assessment 175 10.1 Introduction, 175 10.2 Network Pinch—The Bottleneck of Existing Heat Recovery System, 176 10.3 Identification of Modifications, 179 10.4 Automated Network Pinch Retrofit Approach, 181 10.5 Case Studies for Applying the Network Pinch Retrofit Approach, 183 11 Process Integration Opportunity Assessment 195 11.1 Introduction, 195 11.2 Definition of Process Integration, 196 11.3 Plus and Minus (+/-) Principle, 198 11.4 Grand Composite Curves, 199 11.5 Appropriate Placement Principle for Process Changes, 200 11.6 Examples of Process Changes, 205 PART 3 PROCESS SYSTEM ASSESSMENT AND OPTIMIZATION 225 12 Distillation Operating Window 227 12.1 Introduction, 227 12.2 What is Distillation?, 228 12.3 Distillation Efficiency, 229 12.4 Definition of Feasible Operating Window, 232 12.5 Understanding Operating Window, 232 12.6 Typical Capacity Limits, 253 12.7 Effects of Design Parameters, 255 12.8 Design Checklist, 257 12.9 Example Calculations for Developing Operating Window, 257 12.10 Concluding Remarks, 276 13 Distillation System Assessment 281 13.1 Introduction, 281 13.2 Define a Base Case, 281 13.3 Calculations for Missing and Incomplete Data, 284 13.4 Building Process Simulation, 287 13.5 Heat and Material Balance Assessment, 288 13.6 Tower Efficiency Assessment, 292 13.7 Operating Profile Assessment, 295 13.8 Tower Rating Assessment, 298 13.9 Column Heat Integration Assessment, 300 13.10 Guidelines for Reuse of an Existing Tower, 302 14 Distillation System Optimization 305 14.1 Introduction, 305 14.2 Tower Optimization Basics, 306 14.3 Energy Optimization for Distillation System, 312 14.4 Overall Process Optimization, 318 14.5 Concluding Remarks, 326 PART 4 UTILITY SYSTEM ASSESSMENT AND OPTIMIZATION 327 15 Modeling of Steam and Power System 329 15.1 Introduction, 329 15.2 Boiler, 330 15.3 Deaerator, 333 15.4 Steam Turbine, 334 15.5 Gas Turbine, 338 15.6 Letdown Valve, 339 15.7 Steam Desuperheater, 341 15.8 Steam Flash Drum, 342 15.9 Steam Trap, 342 15.10 Steam Distribution Losses, 344 16 Establishing Steam Balances 345 16.1 Introduction, 345 16.2 Guidelines for Generating Steam Balance, 346 16.3 AWorking Example for Generating Steam Balance, 347 16.4 A Practical Example for Generating Steam Balance, 357 16.5 Verify Steam Balance, 362 16.6 Concluding Remarks, 364 17 Determining True Steam Prices 366 17.1 Introduction, 366 17.2 The Cost of Steam Generation from Boiler, 367 17.3 Enthalpy-Based Steam Pricing, 371 17.4 Work-Based Steam Pricing, 372 17.5 Fuel Equivalent-Based Steam Pricing, 373 17.6 Cost-Based Steam Pricing, 376 17.7 Comparison of Different Steam Pricing Methods, 377 17.8 Marginal Steam Pricing, 379 17.9 Effects of Condensate Recovery on Steam Cost, 384 17.10 Concluding Remarks, 384 18 Benchmarking Steam System Performance 386 18.1 Introduction, 386 18.2 Benchmark Steam Cost: Minimize Generation Cost, 387 18.3 Benchmark Steam and Condensate Losses, 389 18.4 Benchmark Process Steam Usage and Energy Cost Allocation, 394 18.5 Benchmarking Steam System Operation, 396 18.6 Benchmarking Steam System Efficiency, 397 19 Steam and Power Optimization 403 19.1 Introduction, 403 19.2 Optimizing Steam Header Pressure, 404 19.3 Optimizing Steam Equipment Loadings, 405 19.4 Optimizing On-Site Power Generation Versus Power Import, 407 19.5 Minimizing Steam Letdowns and Venting, 412 19.6 Optimizing Steam System Configuration, 413 19.7 Developing Steam System Optimization Model, 417 PART 5 RETROFIT PROJECT EVALUATION AND IMPLEMENTATION 423 20 Determine the True Benefit from the OSBL Context 425 20.1 Introduction, 425 20.2 Energy Improvement Options Under Evaluation, 426 20.3 A Method for Evaluating Energy Improvement Options, 429 20.4 Feasibility Assessment and Make Decisions for Implementation, 442 21 Determine the True Benefit from Process Variations 447 21.1 Introduction, 447 21.2 Collect Online Data for the Whole Operation Cycle, 448 21.3 Normal Distribution and Monte Carlo Simulation, 449 21.4 Basic Statistics Summary for Normal Distribution, 456 22 Revamp Feasibility Assessment 459 22.1 Introduction, 459 22.2 Scope and Stages of Feasibility Assessment, 460 22.3 Feasibility Assessment Methodology, 462 22.4 Get the Project Basis and Data Right in the Very Beginning, 465 22.5 Get Project Economics Right, 466 22.6 Do Not Forget OSBL Costs, 470 22.7 Squeeze Capacity Out of Design Margin, 471 22.8 Identify and Relax Plant Constraints, 472 22.9 Interactions Between Process Conditions, Yields, and Equipment, 473 22.10 Do Not Get Misled by False Balances, 474 22.11 Prepare for Fuel Gas Long, 475 22.12 Two Retrofit Cases for Shifting Bottlenecks, 477 22.13 Concluding Remarks, 480 23 Create an Optimization Culture with Measurable Results 481 23.1 Introduction, 481 23.2 Site-Wide Energy Optimization Strategy, 482 23.3 Case Study of the Site-Wide Energy Optimization Strategy, 487 23.4 Establishing Energy Management System, 492 23.5 Energy Operation Management, 496 23.6 Energy Project Management, 499 23.7 An Overall Work Process from Idea Discovery to Implementation, 500 References, 502 INDEX 503

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Book SynopsisThis handy book provides a single, up-to-date source of information for increasing the life of tool steels through optimized design and manufacturing. Supplying a solid understanding of the metallurgy involved, the text explains how material compositions, manufacturing processes, heat treatments, surface hardening techniques, and coatings affect tool steel properties, grades, and performance. It also explores real-life case studies and failure analyses, offering examples of die-life parameters and hints for modifying tool steels and heat treatments during cutting or forming processes. While the book offers deep coverage of properties, microstructure, and manufacturing, its focus is on describing the performance of each application of this special class of ferrous materials. Provides a single, up-to-date source of information for increasing the life of tool steels through optimized design and manufacturing. Explains how material compositions, maTrade Review"… updates and improves the literature … in a very strategic and important industrial field."—Rosso Mario, Politecnico di Torino, Italy Table of ContentsIntroduction to Tool Steels. Manufacturing of Tool Steels. Physical Metallurgy of Tool Steels. Hot Work Tool Steels. Cold Work Tool Steels. Plastic Mold Tool Steels. High Speed Steels.

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Book SynopsisHello, I'm Jake, a retired production planner. I've been talking to my coffee mate Ben about the factory where I have spent the better part of my life. Believe me, I have seen things go well and even more go very wrong. I'm outside the gate now, but the grapevine is keeping me up to date. Which is why I know that the factory is heading into oblivion, as management does not seem to understand commonsense principles and they are testing the patience of their main customer. But wait, things look like they might change when new management is brought in. This new plant manager might change things around, and thanks to my old friends we can keep on top of things. Do you want to hear my story? The concepts imbedded in the factory's journey capture the leading practices in progressive and proactive management. The commonsense concepts embody the philosophy of collaboration, shared fate, mutual respect, and leveraging the intellectual capital that exists in each and every factory. This book is for you if you want your factory to survive and thrive!

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Book Synopsis

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