The doctoral dissertations of the former Helsinki University of Technology (TKK) and Aalto University Schools of Technology (CHEM, ELEC, ENG, SCI) published in electronic format are available in the electronic publications archive of Aalto University - Aaltodoc.
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Conceptual Approach to Process Integration Efficiency
Mari Tuomaala
Dissertation for the degree of Doctor of Science in Technology to be presented with due permission of the Department of Mechanical Engineering for public examination and debate in Auditorium K216 at Helsinki University of Technology (Espoo, Finland) on the 8th of June, 2007, at 12 noon.
Dissertation in PDF format (ISBN 978-951-22-8788-8) [1441 KB]
Errata (in PDF format)
Dissertation is also available in print (ISBN 978-951-22-8787-1)
Abstract
Various types of models and methods are used to design and analyze industrial processes. Mostly their use deals with partial system efficiencies like utility system efficiency. A model for treating the entire system has been missing. An integrated industrial process consists of interconnected production processes of the process industry (e.g. pulp and paper, metallurgical, chemical and energy production industries).
The thesis presents a conceptual approach to the evaluation of integrated industrial processes. According to research results, efficiency can be categorized into material efficiency, energy efficiency and operational efficiency. These dimensions are described using criteria and case-specific indicators. The criteria and indicators sometimes represent certain perspectives of design, such as economy or environment.
The concept of efficiency can be attached to systems of varying physical scales. In its narrowest context the scale covers equipment and unit processes. In its largest context the scale covers complete production sites. The scale determines which criteria and indicators are emphasized in the evaluation: technical ones are emphasized on the equipment and unit process scale and strategic ones are emphasized on the site scale.
An important part of the proposed concept is the way in which the potential for improvement is dealt with. The potential for improvement is dependent on the life span phase of the mill, the physical scale of the problem and the number of priority criteria (potential in respect of one criterion versus potential in respect of several simultaneous criteria). The potentials are categorized into three groups: 1) structural (theoretical) potentials, 2) technical potentials and 3) economic potentials. The research also indicates that efficiency improvement activities have to be done in close cooperation with company's operational management. The connection is required to prioritize actions and to implement corrective actions.
The developed concept is qualitative and it is applied on case-by-case basis. The concept does not contain a quantitative analysis; it is used to formulate the problem and to select the correct and detailed tools for the work. The results of evaluation can be utilized e.g. to compare unit processes and process concepts against each other.
Keywords: process integration, process industry, efficiency analyses
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© 2007 Helsinki University of Technology
Last update 2011-05-26