Effective distribution of hydrogen in refinery hydrogen networks is a major concern for refiners tackling the stringent specifications on maximum sulphur levels in middle distillates and the increasing global demand of diesel fuel. A major challenge is the implementation of a shift from conventional to ultra-deep methods of desulphurisation. Meanwhile, the capacity of secondary conversion processes such as fluid catalytic cracking (FCC) and hydrocracking in refineries has steadily increased in converting the bottom of the barrel into high-value lighter products resulting in increased levels of hydroprocessing, which exerts a higher demand on refinery hydrogen systems. Previous methodologies on hydrogen network optimization have been developed mainly based on the assumption of fixed hydroprocessing performance with constant hydrogen consumption and light hydrocarbon yields, in order to reduce the complexity of the optimisation problem. Consequently, critical interactions among feed and catalyst properties, hydroprocessor operating conditions, product quality and yields, and hydrogen consumption are usually neglected. This research work involves three major aspects: 1. Development of semi-empirical nonlinear lumped hydrodesulphurisation (HDS) and hydrocracker models that are robust and sufficiently detailed to capture the behaviour of the process with changes in feed characteristics and operating conditions. The formation of light hydrocarbons during HDS reactions have been accounted for. Hydrocracker conversion models and five/six-lumped product yield models for vacuum gas oil (VGO) and vacuum residue (VR) feedstocks have been developed from a combination of first principles and empirical methods based on several process parameters. The proposed models are validated with different feedstocks and shows good agreement with industrial data. 2. Integration of HDS and hydrocracker performance models into refinery hydrogen network models to explore existing interactions between processes and the hydrogen network, and their combined effect on the overall network objective. 3. Optimization of the overall superstructure under different operating scenarios to facilitate the efficient distribution and utilization of hydrogen and the maximization of clean high-value products. The integrated superstructure network model is developed and optimized within the General Algebraic Modelling System (GAMS). The model is representative of the dynamic interactions between hydrodesulphurisation and hydrocracking processes in the refinery hydrogen network as demonstrated by the reproducibility of industrial refinery data. Thus, this work presents a holistic and realistic implementation of refinery hydrogen management technique.

In Canada, coal-fired power plants are the largest anthropogenic point sources of atmospheric CO₂. The most promising near-term strategy for mitigating CO₂ emissions from these facilities is the post-combustion capture of CO₂ using MEA (monoethanolamine) with subsequent geologic sequestration. While MEA absorption of CO₂ from coal-derived flue gases on the scale proposed above is technologically feasible, MEA absorption is an energy intensive process and especially requires large quantities of low-pressure steam. It is the magnitude of the cost of providing this supplemental energy that is currently inhibiting the deployment of CO₂ capture with MEA absorption as means of combatting global warming. The steam cycle of a power plant ejects large quantities of low-quality heat to the surroundings. Traditionally, this waste has had no economic value. However, at different times and in different places, it has been recognized that the diversion of lower quality streams could be beneficial, for example, as an energy carrier for district heating systems. In a similar vein, using the waste heat from the power plant steam cycle to satisfy the heat requirements of a proposed CO₂ capture plant would reduce the required outlay for supplemental utilities; the economic barrier to MEA absorption could be removed. In this thesis, state-of-the-art process simulation tools are used to model coal combustion, steam cycle, and MEA absorption processes. These disparate models are then combined to create a model of a coal-fired power plant with integrated CO₂ capture. A sensitivity analysis on the integrated model is performed to ascertain the process variables which most strongly influence the CO₂ energy penalty. From the simulation results with this integrated model, it is clear that there is a substantial thermodynamic advantage to diverting low-pressure steam from the steam cycle for use in the CO₂ capture plant. During the course of the investigation, methodologies for using Aspen Plus® to predict column pressure profiles and for converging the MEA absorption process flowsheet were developed and are herein presented.

Background:China could be seemed as a highly developing country. There are many opportunities and challenges inChina. Its preferential policies and huge potential market attract a lot of foreign companies to come toChina. Meanwhile, Chinese government encourages the development of domestic enterprises. Therefore, at present there mainly coexist three forms of enterprises inChina: foreign-funded companies, private companies and state-controlling companies. In order to enhance competitiveness, almost every company in china has its own supply chain network. Supply Chain management plays an important role in Chinese companies. Research question: 1.     What is the current situation of purchasing process and purchasing process integration for some manufacturers of different ownerships in China?   2.     How can purchasing process be integrated for some manufacturers of different ownerships in China from manufacture’s perspectives?   Purpose: The purpose of this thesis is to study the current situation in purchasing process integration in Chinese manufacturing industry of three kinds of ownership and evaluate the purchasing process of three kinds of companies in China. In addition, it gives some suggestions to remove potential obstacles and optimize the purchasing process; and aims to help the companies to gain competitive advantage in the long term.   Method: The empirical foundation for this thesis is intended to be on multiple case study method. It studies of the three types of manufacturing enterprises in China. To represent these three types of companies, three companies are chosen from each as selected research objects. Data is collected through semi-structure interviews, so the questionnaire would be open-ended. Long-distance telephone interview with purchasing managers and material managers separately for each company would be adopted.   Conclusion: The purchasing process of three companies who represent three different types of ownership is studied. It studies the current situation in purchasing process integration in Chinese manufacturing industry of three kinds of ownership and evaluates the purchasing process of three kinds of companies in China. Then the obstacles in purchasing process are found out. Then suggestions on purchasing process integration are used to tackle these obstacles.   Future Work: This thesis focuses on three manufacturing companies in China. The result of this thesis cannot represent all the obstacles in purchasing process in manufacturing industry in China. But the purchasing process, characteristics, strength and weakness are similar in the same type of ownership. Meanwhile, the recommendation on purchasing process integration also cannot solve all the obstacles found, due to the companies’ own condition. In future research, it recommends to add more research companies. Furthermore, more studies could be included to identify common obstacles and dig out solutions related to purchasing process integration in Chinese manufacturing industry.

The goal of this work is to develop a conceptual framework and computational tools for the optimization of utility systems in the process industries. The emphasis is devoted to the development of systematic design techniques aimed at identifying modifications to the process and the associated utility-systems to jointly optimize the process and the utility system. The following contributions describe the specific results of this work: • Development of shortcut methods for modeling and optimizing steam systems and basic thermodynamic cycles with the objective of using these methods in the optimization of combined heat and power. To enable efficient mathematical programming formulations, simple yet accurate correlations have been developed for the thermodynamic properties of steam in the utility system. • Optimization of multi-level steam system for combined process requirements and power cogeneration. A general procedure is developed to determine rigorous cogeneration targets and the optimal configuration of the system with the associated design and operating variables. • Graph theory methods are also used to optimize the pipeline layout in the plant for the distributing the utilities. • Finally, because of the nonconvex nature of much of the developed optimization formulations, a global optimization method has also been suggested by using interval analysis and simulated annealing. The techniques proposed in this work are compared to previous works and their applicabilities are presented in case studies. These techniques outperform previously suggested ones in terms of the accuracy, computational efficiency and/or optimality.

With the increasing stringency on sulfur content in petrodiesel, there is a growing tendency of broader usage of ultra low sulfur diesel (ULSD) with sulfur content of 15 ppm. Refineries around the world should develop cost-effective and sustainable strategies to meet these requirements. The primary objective of this work is to analyze alternatives for producing ULSD. In addition to the conventional approach of revamping existing hydrotreating facilities, the option of blending petrodiesel with biodiesel is investigated. Blending petrodiesel with biodiesel is a potentially attractive option because it is naturally low in sulfur, enhances the lubricity of petrodiesel, and is a sustainable energy resource. In order to investigate alternatives for producing ULSD, several research tasks were undertaken in this work. Firstly, base-case designs of petrodiesel and biodiesel production processes were developed using computer-aided tools ASPEN Plus. The simulations were adjusted until the technical criteria and specifications of petrodiesel and biodiesel production were met. Next, process integration techniques were employed to optimize the synthesized processes. Heat integration for petrodiesel and biodiesel was carried out using algebraic, graphical and optimization methods to maximize the integrated heat exchange and minimize the heating and cooling utilities. Additionally, mass integration was applied to conserve material resources. Cost estimation was carried out for both processes. The capital investments were obtained from ASPEN ICARUS Process Evaluator, while operating costs were calculated based on the updated chemical market prices. The total operating costs before and after process integration were calculated and compared. Next, blending optimization was performed for three blending options with the optimum blend for each option identified. Economic comparison (total annualized cost, breakeven analysis, return on investment, and payback period) of the three options indicated that the blending of ULSD with chemical additives was the most profitable. However, the subsequent life-cycle greenhouse gas (GHG) emission and safety comparisons demonstrated that the blending of ULSD with biodiesel was superior.

This work focused upon design and operation of biodiesel production facilities in support of the broader goal of developing a strategic approach to the development of biorefineries. Biodiesel production provided an appropriate starting point for these efforts. The work was segregated into two stages. Various feedstocks may be utilized to produce biodiesel, to include virgin vegetable oils and waste cooking oil. With changing prices, supply, and demand of feedstocks, a need exists to consider various feedstock options. The objective of the first stage was to develop a systematic procedure for scheduling and operation of flexible biodiesel plants accommodating a variety of feedstocks. This work employed a holistic approach and combination of process simulation, synthesis, and integration techniques to provide: process simulation of a biodiesel plant for various feedstocks, integration of energy and mass resources, optimization of process design and scheduling, and techno-economic assessment and sensitivity analysis of proposed schemes. An optimization formulation was developed to determine scheduling and operation for various feedstocks and a case study solved to illustrate the merits of the devised procedure. With increasing attention to the environmental impact of discharging greenhouse gases (GHGs), there has been growing public pressure to reduce the carbon footprint associated with fossil fuel use. In this context, one key strategy is substitution of fossil fuels with biofuels such as biodiesel. Design of biodiesel plants has traditionally been conducted based on technical and economic criteria. GHG policies have the potential to significantly alter design of these facilities, selection of feedstocks, and scheduling of multiple feedstocks. The objective of the second stage was to develop a systematic approach to design and scheduling of biodiesel production processes while accounting for the effect of GHG policies. An optimization formulation was developed to maximize profit of the process subject to flowsheet synthesis and performance modeling equations. The carbon footprint is accounted for through a life cycle analysis (LCA). The objective function includes a term reflecting the impact of the LCA of a feedstock and its processing to biodiesel. A multiperiod approach was used and a case study solved with several scenarios of feedstocks and GHG policies.

With the significant progress of information system, information technique has been the essential surviving key to a business. Enterprise adopts various information systems so as to be able to aware of the ever-changing environments coming from either internally or externally and still maintain stable and reliable management mechanism. Enterprise Resources Planning (ERP) has been widely applied to the integration of companies¡¦ internal processing systems. Nevertheless, focusing too much on either structure view, or process view, or isolated structure-process views always hinds the success of implementing an ERP within a company. Consequently, to be classified as a blue ocean enterprise, this research urges companies describe ERP with Distribution ERP Architecture Model (DERPAM), hence structure-process-integration constructing distribution ERP systems. In such case, combination of 80% distribution ERP and 20% core competence of each unique company becomes highly achievable. Outstandingly, DERPAM helps companies derive an optimized distribution ERP.

A hierarchical procedure is developed to determine maximum overall yield of a process and optimize process changes to achieve such a yield. First, a targeting procedure is developed to identify an upper bound of the overall yield ahead of detailed design. Several mass integration strategies are proposed to attain maximum yield. These strategies include rerouting of raw materials, optimization of reaction yield, rerouting of product from undesirable outlets to desirable outlets, and recycling of unreacted raw materials. Path equations are tailored to provide the appropriate level of detail for modeling process performance as a function of the optimization variables pertaining to design and operating variables. Interval analysis is used as an inclusion technique that provides rigorous bounds regardless of the process nonlinearities and without enumeration. Then, a new approach for identification of cost-effective implementation of maximum attainable targets for yield is presented. In this approach, a mathematical program was developed to identify the maximum feasible yield using a combination of iterative additions of constraints and problem reformulation. Next, cost objectives were employed to identify a cost-effective solution with the details of design and operating variables. Constraint convexification was used to improve the quality of the solution towards globability. A trade-off procedure between the saving and expenses for yield maximization problem is presented. The proposed procedure is systematic, rigorous, and computationally efficient. A case study was solved to demonstrate the applicability and usefulness of the developed procedure.

Orientador: Roger Josef Zem / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Quimica / Made available in DSpace on 2018-08-11T12:32:37Z (GMT). No. of bitstreams: 1 Herkenhoff_RogerioGeaquinto_D.pdf: 1183174 bytes, checksum: f7777dadb80f82afeeb6190f4bb190e9 (MD5) Previous issue date: 2008 / Nesta tese é proposta uma nova estratégia para o projeto de reestruturação de redes de trocadores de calor, qualquer que seja seu objetivo: ampliação de carga ou modificações das condições operacionais, otimização da recuperação de energia, melhor atendimento das demandas do processo industrial, etc. Esta proposta é baseada num método consagrado, conhecido como "Pinch Design Method" e originalmente restrito ao projeto de redes novas ("grass-root design"), e inclui toda a formulação e demais requisitos necessários para sua extensão à reestruturação de redes existentes. Tanto o método original quanto a adaptação agora proposta têm origem termo dinâmica e montagem "manual" da rede, em oposição à (síntese) automatizada. A base conceitual da chamada "Pinch Technology" é extensivamente apresentada e discutida na tese, que a!nda inclui vários estudos de caso para demonstrar sua atualidade, através da confrontação com os resultados típicos da síntese automatizada de redes novas. o método proposto é basicamente dedicado ao pré-estabelecimento dos objetivos de projeto, com a posterior utilização das regras de síntese e demais ferramentas do método original. Em comparação com o procedimento tradicional sugerido no contexto da "Pinch Technology", o método proposto propõe objetivos mais ambiciosos, e ainda assim, realistas (na remontagem da rede, os objetivos previamente estabelecidos podem ser alcançados). O processo de remontagem da rede, embora mais difícil que a síntese de redes novas, também é facilitado em relação ao método tradicional que, além disto, tem aplicação mais restrita. A reestruturação automatizada de redes não é contemplada neste estudo, mesmo porque ela ainda não dispõe de produtos largamente aprovados, para uso geral. Na parte final da tese, três exemplos complexos demonstram as mais relevantes vantagens do método proposto sobre o método tradicional manual (nos casos em que ele se aplica), e sua maior (ou irrestrita) aplicabilidade / Abstract: In this thesis, it is proposed a new design strategy for restructuring existing heat exchanger networks, regardless of its objective: heat recovery optimization, better or full achievement of the industrial process demands, reutilization under different operational conditions, plant capacity expansion, etc. The proposed strategy is based on the widely approved Pinch Design Method, originally restricted to the design of new networks (grass-root design), and inc1udes all formulatioIÍ and additional requirements for its extension to existing networks (retrofits, revamps, etc.). Both the original and the proposed method are thermodynamically based, with manual construction of the network structure, in opposition to the automated synthesis. The conceptual basis of the Pinch Technology is extensively presented and discussed in the.thesis, which also inc1udes several case studies to demonstrate its realism, when confronted to the typical results of the automated synthesis of new networks. The proposed method is basically devoted to the pre-establishment of design objectives (targeting), and takes laler advantage of the synthesis rules and accessory tools of the original methodology. In comparison with the most traditional non-automated Pinch method, the new strategy suggests more ambitious design targets, but quite still realistic (for all case studies, it was found a modified structure to meet the targets). Because of the similarity with a new design, finding a modified structure to achieve 'the targets is alsG easier than in the traditional method, whose application is also more restricted. Automated restructuring of existing networks is not inc1uded in our case studies. as no corresponding reliable product is commercially available for general use. Finally, three complex examples demonstrate the most relevant advantages ane realism ofthe proposed method, compared to the traditional one (when applicable), as wel as its wider (or unrestricted) applicability / Doutorado / Sistemas de Processos Quimicos e Informatica / Doutor em Engenharia Química

This research proposes a novel Retrofit Design Approach based on process simulation and the Response Surface Methodology (RSM).Retrofit Design Approach comprises: 1) a diagnosis stage in which the variables are screened and promising variables to improve system performance are identified through a sensitivity analysis, 2) an evaluation stage in which RSM is applied to assess the impact of those promising variables and the most important factors are determined by building a reduced model from the process response behaviour, and 3) an optimisation stage to identify optimal conditions and performance of the system, subject to objective function and model constraints. All these stages are simulation-supported. The main advantages of the proposed Retrofit Design Approach using RSM are that the design method is able to handle a large industrial-scale design problem within a reasonable computational effort, to obtain valuable conceptual insights of design interactions and economic trade-off existed in the system, as well as to systematically identify cost-effective solutions by optimizing the reduced model based on the most important factors. This simplifies the pathway to achieve pseudo-optimal solutions, and simultaneously to understand techno-economic and system-wide impacts of key design variables and parameters. In order to demonstrate the applicability and robustness of the proposed design method, the proposed Retrofit Design Approach has been applied to two case studies which are based on existing gas processing processes. Steady-state process simulation using Aspen Plus TM® has been carried out and the simulation results agree well with the plant data. Reduced models for both cases studies have been obtained to represent the techno-economic behaviour of plants. Both the continuous and discrete design options are considered in the retrofitting of the plant, and the results showed that the Retrofit Design Approach is effective to provide reliable, cost-effective retrofit solutions which yield to improvements in the studied processes, not only economically (i.e. cost and product recovery), but also environmentally linked (i.e. CO₂ emissions and energy efficiency). The main retrofitting solutions identified are, for the first case, column pressure change, pump-around arrangement and additional turbo-expansion capacity, while for the second case, columns pressure change, trays efficiency, HEN retrofit arrangements (re-piping) and onsite utility generation schemes are considered. These promising sets of retrofit design options were further investigated to reflect implications of capital investment for the retrofit scenarios, and this portfolio of opportunities can be very useful for supporting decision-making procedure in practice. It is important to note that in some cases a cost-effective retrofit does not always require structural modifications. In conclusion, the proposed Retrofit Design Approach has been found to be a reliable approach to address the retrofit problem in the context of industrial applications.