The replacement of fossil resources through renewable alternatives is one way to mitigate global climate change. Biomass is the only renewable source of carbon available for replacing oil as a refining feedstock. Therefore, it needs to be utilized not just as a fuel but for both biochemical and thermochemical conversion through biorefining. Optimizing and combining various conversion processes using a system perspective to maximize the valorization, biomass usage, and environmental benefits is of importance. This thesis work has evaluated the integration opportunities for various thermochemical conversion processes within a biorefinery system. The aim for all evaluated concepts were syngas production through gasification or reforming. Two potential residue streams from an existing biorefinery were evaluated as gasification feedstocks, thereby combining biochemical and thermochemical conversion. Torrefaction as a biomass pretreatment for gasification end-use was evaluated based on improved feedstock characteristics, process benefits, and integration aspects. A system concept, “Bio2Fuels”, was suggested and evaluated for low-temperature slow pyrolysis as a way to achieve simultaneous biomass refinement and transport driven CO2 negativity. Syngas was identified as a very suitable intermediate product for residue streams from biochemical conversion. Resulting syngas composition and quality showed hydrolysis residue as suitable gasification feedstock, providing some adjustments in the feedstock preparation. Gasification combined with torrefaction pretreatment demonstrated reduced syngas tar content. The co-gasification of biogas and wood in a FBG was successfully demonstrated with increased syngas H2/CO ratio compared to wood gasification, however high temperatures (≥1000°C) were required for efficient CH4 conversion. The demonstrated improved feedstock characteristics for torrefied biomass may facilitate gasification of biomass residue feedstocks in a biorefinery. Also, integration of a torrefaction unit on-site at the biorefinery or off-site with other industries could make use of excess low-value heat for the drying step with improved overall thermal efficiency. The Bio2Fuels concept provides a new application for slow pyrolysis. The experimental evaluation demonstrated significant hydrogen and carbon separation, and no significant volatilization of ash-forming elements (S and Cl excluded)  in low-temperature (<400°C) pyrolysis. The initial reforming test showed high syngas CH4 content, indicating the need for catalytic reforming. The collective results from the present work indicate that the application of thermochemical conversion processes into a biorefinery system, making use of by-products from biochemical conversion and biomass residues as feedstocks, has significant potential for energy integration, increased product output, and climate change mitigation.

The master’s thesis is focused on familiarization with modern techniques and procedures of process system engineering for identification of energy savings. In this case, process system engineering is applied to the issue of heat exchanger networks and in order to save energy, their retrofit is solved here. The current network pinch method, which uses mathematical programming options, is described for the retrofit of the heat exchanger networks. The method is presented in comparison to older development methods, mainly with the PDM. In addition, the calculation procedure is also developed by this method and in the Maple software environment it is applied to the case of heat exchanger network retrofit in the process of hydrogenation refining of oil. Part of the thesis is an evaluation of the results obtained, including a discussion of the properties of the method used.

Aus der Einleitung: "Bedingt durch eine geforderte, lokale Präsenz eines global agierenden Unternehmens gegenüber weltweiten Kunden sowie durch global verteiltes Engineering, Produktion und Service sind Unternehmen zunehmend in der Pflicht, sich global zu positionieren. Auch die Verlagerung von Engineeringaufgaben zu externen Zulieferern und Partnern erfordern organisatorische sowie prozesstechnische Maßnahmen, die durch eine entsprechende informationstechnische Unterstützung flankiert werden müssen. Für diese Unterstützung können sogenannte PLM-Systemumgebungen genutzt werden, die sich auf PDM-Systemen abstützen."

This dissertation is a complete unifying approach to the fundamentals, industrial applications and software implementation of an important branch of process-engineering principles and practice, called process integration. The latter refers to the system-oriented, thermodynamically-based and integrated approaches to the analysis, synthesis and retrofit of process plants, focusing on integrating the use of materials and energy, and minimizing the generation of emissions and wastes. This work extends process integration to include applications for industrial water reuse and wastewater minimization and presents previous developments in a unified manner. The basic ideas of process integration are: (1) to consider first the big picture by looking at the entire manufacturing process as an integrated system; (2) to apply process-engineering principles to key process steps to establish a priori targets for the use of materials and energy, and for the generation of emissions and wastes; and (3) to finalize the details of the process design and retrofit later to support the integrated view, particularly in meeting the established targets. Pinch technology is a set of primarily graphical tools for analyzing a process plant's potential for energy conservation, emission reduction and waste minimization. Here, we identify targets for the minimum consumption of heating and cooling utilities, mass-separating agents, freshwater consumption, wastewater generation and effluent treatment and propose economical grassroots designs and retrofit projects to meet these goals. An emerging alternative approach to pinch technology, especially when analyzing complex water-using operations and effluent-treatment systems, is mathematical optimization. We solve nonlinear programming problems for simple water-using operations through readily available commercial software. However, more complex, nonconvex problems require sophisticated reformulation techniques to guarantee optimality and are the subject of continuing academic and commercial development. This work develops the principles and practice of an environmentally significant breakthrough of process integration, called water-pinch technology. The new technology enables the practicing engineers to maximize water reuse, reduce wastewater generation, and minimize effluent treatment through pinch technology and mathematical optimization. It applies the technology in an industrial water-reuse demonstration project in a petrochemical complex in Taiwan, increasing the average water reuse (and thus reducing the wastewater treatment) in the five manufacturing facilities from 18.6% to 37%. This dissertation presents complete conceptual and software developments to unify the known branches of process integration, such as heat and mass integration, and wastewater minimization, and explores new frontiers of applications to greatly simplify the tools of process integration for practicing engineers. / Ph. D.

Without a doubt, there is a consensus around the international community which suggests that our current way of life is unsustainable for a healthy planet, society and economy. One focal point that should be taken deeply into consideration is the steel industry as, globally, it accounts for 8% of global emissions. Thus, there is a dire need to incorporate drastic measures, if one wishes to reach net-zero emissions by 2050, in accordance with the Paris Agreement of 2015. Electric Arc Furnaces are seeing a rapid implementation in the steel industry. However, at 0.5 tonnes of CO2 emitted per tonne of liquid steel produced, this emissions rating is still significant considering the amount of steel being produced annually. Additionally, these furnaces emit off-gases which must be treated from the dust. This leaves operators with a conundrum as the dust content compromises the use of waste heat recovery boilers for energy recovery, due to constant breakdowns. Therefore, this study aims to analyse the feasibility of using bioenergy and carbon capture and utilisation (CCU) concepts to capitalise on the high off-gas energy and emissions content to remedy the dust issue, whilst producing higher value products. The proposed concept evaluates the effectiveness of using the off-gas as the energy carrier and feed-stock for a biogasificaiton unit. Three different cases based on different EAF off-gas compositions have been investigated. Case 1 suggested that the off-gas composition is very CO2-heavy, whichled to investigating the option of adopting a CO2 biogasification concept to directly use the CO2. Case 1 performed the best in terms of CO2 utilisation efficiency; being 0.293. The system energy utilisation also noted that 49.3% of the inlet streams energy was transferred to the desired product. On a broader picture, this means that around 11% of the total energy coming out of the EAF would be utilised in producing a value-added product in the form of syngas. This contrasts with allowing around 33% of the energy in the EAF either being completely dissipated to the environment or converting it into electricity via waste heat recovery. The following two cases, Case 2 and 3, indicate EAF off-gas composition containing 72% and 40% nitrogen respectively. For Cases 2 and 3, a steam biogasification process was integrated which did not yield positive results for CO2 utilisation, since is a more promising gasifying agent. In addition, significant energy from EAF off-gas is used in raising the temperature of steam to the design temperature of the gasifier. However, although the CO2 was not directly used in this part of the process, it allows for other opportunities of process integration, for example the reverse water-gas shift step.

對企業而言，Internet和電子商務的興起提供了一個全新的商業交易方式。許多企業企圖融合新的資訊科技與企業流程，讓他們可以跨越企業間的藩籬進而互相分享價值鏈中的決策、工作流與資訊。然而，當企業嘗試著以其內部的資訊系統與交易夥伴溝通時，卻發現到處都是問題。雖然XML 提供了一個多功能的且健全的資料交換格式，但仍然不夠，必須有一個流程整合的標準來進行企業間交易流程的塑模(modeling)、部署(deploying)、執行(executing)以及管理(managing)。在本篇研究中，將探討企業對企業間協同流程的整合，並且發展一個以ebXML為基礎的協同商務企業流程模式。基於UN/CEFACT Modeling Methodology (UMM)此一致性的塑模方法論，本研究以邏輯化且系統化的方式來發現並詳細表達出國際物流業的跨企業交易流程，並以ebXML流程分析表格(ebXML Business Process Analysis Worksheets)為流程塑模輔助工具，進行國際物流業流程分析結果的記錄與表達。 基於此一ebXML為基礎之流程模式，本研究開發了一個企業間流程整合的雛形系統，藉以證明此企業流程模式是可行的，同時提出一個即時有效率的企業間電子商務可行方案。 / Internet technology and electronic commerce (EC) have brought up a complete overhaul on the information and communication technology infrastructure to do business in a new manner where companies try to leverage new technologies to enable a set of complex cross-enterprise business processes allowing entire value chains to share decision-making, workflow, capabilities, and information with each other. However, companies often have problems in making their internal information technology (IT) systems communicate with their partners. Although eXtensible Markup Language (XML) represents the most versatile and robust format for exchanging business information, there is also a need for process integration standard that enables processes to be modeled, deployed, executed, and managed. In this research, business-to-business collaboration process integration issues have been studied and an ebXML-based Collaborative Commerce Business Process Model is developed. According to a consistent modeling methodology, UN/CEFACT Modeling Methodology (UMM), we identify and specify the inter-enterprise business processes of the global logistics industry in a logical and systematical way. The ebXML Business Process Analysis Worksheets is used as modeling aids to record and represent analysis results of global logistics industry. Based on the ebXML-based business process model, we develop a B2B process integration prototype system which shows that the business process model is feasible and suggests a possible solution for real-time and efficient B2B electronic commerce.

There has been renewed significance for innovative energy conversion technologies, particularly the heat recovery-to-power technologies for sustainable power generation from renewable energies and waste heat. This is due to the increasing concern over high demand for electricity, energy shortage, global warming and thermal pollution. Among the innovative heat recovery-to- power technologies, the proposed trilateral flash cycle (TFC) is a promising option, which presents a great potential for development. Unlike the Rankine cycles, the TFC starts the working fluid expansion from the saturated liquid condition rather than the saturated, superheated or supercritical vapour phase, bypassing the isothermal boiling phase. The challenges associated with the need to establish system design basis and facilitate system configuration design-supporting analysis from proof-of-concept towards a market-ready TFC technology are significant. Thus, there is a great need for research to improve the understanding of its operation, behaviour and performance. The objective of this study is to develop and establish simulation tools of the TFCs for improving the understanding of their operation, physics of performance metrics and to evaluate novel system configurations for low-grade heat recovery-to-power generation. This study examined modelling and process simulation of the TFC engines in order to evaluate their performance metrics, predictions for guiding system design and parameters estimations. A detailed thermodynamic analysis, performance optimization and parametric analysis of the cycles were conducted, and their optimized performance metrics compared. These were aimed at evaluating the effects of the key parameters on system performances and to improve the understanding of the performance behaviour. Four distinct system configurations of the TFC, comprising the simple TFC, TFC with IHE, reheat TFC and TFC with feed fluid-heating (or regenerative TFC) were examined. Steady-state steady-flow models of the TFC power plants, corresponding to their thermodynamic processes were thermodynamically modelled and implemented using engineering equation solver (ESS). These models were used to determine the optimum synthesis/ design parameters of the cycles and to evaluate their performance metrics, at the subcritical operating conditions and design criteria. Thus, they can be valuable tools in the preliminary prototype system design of the power plants. The results depict that the thermal efficiencies of the simple TFC, TFC with IHE, reheat TFC and regenerative TFC employing n-pentane are 11.85 - 21.97%, 12.32 - 23.91%, 11.86 - 22.07% and 12.01 - 22.9% respectively over the cycle high temperature limit of 393 - 473 K. These suggest that the integration of an IHE, fluid-feed heating and reheating in optimized design of the TFC engine enhanced the heat exchange efficiencies and system performances. The effects of varying the expander inlet pressure at the cycle high temperature and expander isentropic efficiency on performance metrics of the cycles were significant. They have assisted in selecting the optimum-operating limits for the maximum performance metrics. The thermal efficiencies of all the cycles increased as the inlet pressures increased from 2 - 3 MPa and increased as the expander isentropic efficiencies increased from 50 - 100%, while their exergy efficiencies increased. This is due to increased net work outputs that suggest optimal value of pressure ratios between the expander inlets and their outlets. A comprehensive evaluation depicted that the TFC with IHE attained the best performance metrics among the cycles. This is followed by the regenerative TFC whereas the simple TFC and reheat TFC have the lowest at the same subcritical operating conditions. The results presented show that the performance metrics of the cycles depend on the system configuration, and the operating conditions of the cycles, heat source and heat sink. The results also illustrate how system configuration design and sizing might be altered for improved performance and experimental measurements for preliminary prototype development.

There has been renewed significance for innovative energy conversion technologies, particularly the heat recovery-to-power technologies for sustainable power generation from renewable energies and waste heat. This is due to the increasing concern over high demand for electricity, energy shortage, global warming and thermal pollution. Among the innovative heat recovery-to- power technologies, the proposed trilateral flash cycle (TFC) is a promising option, which presents a great potential for development. Unlike the Rankine cycles, the TFC starts the working fluid expansion from the saturated liquid condition rather than the saturated, superheated or supercritical vapour phase, bypassing the isothermal boiling phase. The challenges associated with the need to establish system design basis and facilitate system configuration design-supporting analysis from proof-of-concept towards a market-ready TFC technology are significant. Thus, there is a great need for research to improve the understanding of its operation, behaviour and performance. The objective of this study is to develop and establish simulation tools of the TFCs for improving the understanding of their operation, physics of performance metrics and to evaluate novel system configurations for low-grade heat recovery-to-power generation. This study examined modelling and process simulation of the TFC engines in order to evaluate their performance metrics, predictions for guiding system design and parameters estimations. A detailed thermodynamic analysis, performance optimization and parametric analysis of the cycles were conducted, and their optimized performance metrics compared. These were aimed at evaluating the effects of the key parameters on system performances and to improve the understanding of the performance behaviour. Four distinct system configurations of the TFC, comprising the simple TFC, TFC with IHE, reheat TFC and TFC with feed fluid-heating (or regenerative TFC) were examined. Steady-state steady-flow models of the TFC power plants, corresponding to their thermodynamic processes were thermodynamically modelled and implemented using engineering equation solver (ESS). These models were used to determine the optimum synthesis/ design parameters of the cycles and to evaluate their performance metrics, at the subcritical operating conditions and design criteria. Thus, they can be valuable tools in the preliminary prototype system design of the power plants. The results depict that the thermal efficiencies of the simple TFC, TFC with IHE, reheat TFC and regenerative TFC employing n-pentane are 11.85 - 21.97%, 12.32 - 23.91%, 11.86 - 22.07% and 12.01 - 22.9% respectively over the cycle high temperature limit of 393 - 473 K. These suggest that the integration of an IHE, fluid-feed heating and reheating in optimized design of the TFC engine enhanced the heat exchange efficiencies and system performances. The effects of varying the expander inlet pressure at the cycle high temperature and expander isentropic efficiency on performance metrics of the cycles were significant. They have assisted in selecting the optimum-operating limits for the maximum performance metrics. The thermal efficiencies of all the cycles increased as the inlet pressures increased from 2 - 3 MPa and increased as the expander isentropic efficiencies increased from 50 - 100%, while their exergy efficiencies increased. This is due to increased net work outputs that suggest optimal value of pressure ratios between the expander inlets and their outlets. A comprehensive evaluation depicted that the TFC with IHE attained the best performance metrics among the cycles. This is followed by the regenerative TFC whereas the simple TFC and reheat TFC have the lowest at the same subcritical operating conditions. The results presented show that the performance metrics of the cycles depend on the system configuration, and the operating conditions of the cycles, heat source and heat sink. The results also illustrate how system configuration design and sizing might be altered for improved performance and experimental measurements for preliminary prototype development.

Dans un contexte de transition énergétique et numérique, L’Usine du Futur se définit commeéconome en énergie, mais aussi agile grâce à des moyens de production flexibles etreconfigurables. Conférer ces propriétés aux procédés existants est un challenge complexe quiinduit souvent une réorganisation des unités. Dans ce cadre, la méthodologie RREFlex a pourobjectif de proposer des solutions alternatives d’intégration énergétique à la fois viables, robusteset adaptables via le remodelage des réseaux d’échangeurs de chaleur déjà installés.Contrairement à la conception initiale consistant à réaliser de manière conjointe la conception duprocédé et du réseau d’échangeur de chaleur associé, l’exercice de remodelage d’unitésexistantes peut s’avérer sensiblement plus complexe. En effet, il s’inscrit souvent dans unedémarche d’amélioration continue sur des installations ayant déjà connu au cours de leur vie destransformations pour faire face aux évolutions de la demande ou à de nouvelles contraintesenvironnementales. Aujourd’hui, nombre d’analyses de récupération énergétique sont réaliséessur les sites industriels mais celles-ci ne donnent pas nécessairement lieu à des réalisationsconcrètes. Les raisons le plus souvent invoquées sont d’ordre financières mais aussi, pratiques.En effet, les solutions proposées ne sont pas toujours réalistes d’un point de vue opérationnellecar elles tiennent rarement compte de la variabilité du procédé, soit due à des perturbations nonmaitrisées sur les températures et les débits, soit due à la présence de multiples points defonctionnement (changement de campagne, évolution de la charge, etc.). De plus, ces solutionstiennent peu compte des contraintes spécifiques du site étudié (topologie des unités, compatibilitédes courants, sécurité, etc.), la formulation a priori de ces dernières ne pouvant être exhaustive.L’outil RREFlex - outil Robuste pour la synthèse de Réseaux d’Echangeurs Flexibles - a étédéveloppée pour pallier autant que possible ces limites. S’appuyant sur une analyse statistiquedes historiques de mesures remontés en salle de contrôle, un premier module - EDiFy : EnhancedData collection for Flexibility analysis - permet de localiser et de caractériser les différents cas demarche des unités. Notamment, la valeur moyenne et la variance des données caractéristiques duprocédé (températures, flux calorifiques) sont estimées pour chaque cas de marche. Ce jeu dedonnées étant souvent incomplet, il est nécessaire d’avoir recours à un modèle de simulation duprocédé pour le compléter et valider la cohérence des données mesurées pour chaque cas demarche potentiellement identifié. Sur cette base, une seconde étape dédiée au diagnosticénergétique permet d’évaluer la pertinence des échangeurs de récupération déjà installés. Cetteanalyse permet d’identifier et de prioriser un ensemble de scenarii de remodelage considéréscomme prometteurs. Chacun d’eux est défini par la liste des échangeurs à reconsidérer et uncertain nombre de paramètres de configuration. Chaque scenario retenu est alors exploité pour lasynthèse du réseau d’échangeurs associé. Cette étape s’appuie sur un modèle de programmationlinéaire mixte multi-période (PLM) pour déterminer la nouvelle topologie du réseau d’échangeurs.Dans ce cadre, le modèle a évidemment la possibilité d’introduire de nouveaux échangeurs maisaussi de déplacer les échangeurs existants et conservés dans un scénario donné, tant qu’ilscouplent la même paire de courant qu’initialement. Les réseaux obtenus sont donc adaptables auxdifférents cas de marche identifiés à la première étape et reconfigurable grâce à l’implantation deby-pass. Le panel de réseaux proposés est enfin évalué et classé au moyen d’indicateurs deperformance, dont notamment la robustesse vis-à-vis de la variabilité du procédé. L’approche aété validée sur deux sites de dimension industrielle: un procédé de fabrication de MVC et un trainde préchauffe de pétrole brut / In a context of numerical and energy transition, the Factory of the Future is meant to be moreenergy efficient but also smarter and agile through the use of flexible and reconfigurableproduction means. Enabling existing processes to achieve those properties is a difficult challengewhich often induces a reorganization of the units. In this context, RREFlex methodology wasdeveloped to provide several alternatives heat integration solutions both viable, robust andadaptable through the retrofitting of existing heat exchanger networks. Unlike grass-root design,which consists in designing both the process and the heat exchanger network at the same time(and thus, allowing many possibilities), retrofitting existing units can be a lot more complex.Indeed, as part of a continuous improvement process of the production, the plants have oftenalready undergone transformations during their life to cope with changes in demand or newenvironmental constraints. Currently, numerous energy recovery analysis are performed onindustrial sites but do not necessarily involves concrete industrial measures. The main reasons forthe lack of results are mainly financial but also practical. The provided solutions are often nonrealistic in terms of operability because of the lack of accounting for the variability of the process,whether due to external disturbances on temperatures and flowrates or due to multiple operatingconditions (many production campaigns, evolution in process load, etc.). Moreover, thosesolutions also do not take on-site constraints into account (units topology, process streamscompatibility, safety, etc.), as it is difficult to apprehend such constraints. The RREFlex module(Robust software tool for the synthesis of Flexible Heat Exchanger Networks), was developed toassess these issues. Based on a statistical analysis of historical data extracted from on-sitemeasurements, a first module - EDiFy : Enhanced Data collection for Flexibility analysis – enablesthe location and characterization of the multiple steady state regimes. The mean value andvariance of operating conditions characterizing the process (e.g. temperature, heat flow) areestimated for each steady state. As this data set is usually incomplete, it is necessary to use asimulation model of the process to complete and validate the consistency of the measurements ofeach identified steady state.Based upon those data, an energy diagnosis step enables the assessment of each existing heatexchanger liability. This analysis results in the identification and classification of several promisingretrofitting scenarios. Each one is defined by a list of heat exchangers to reconsider and severalconfiguration parameters.Each selected scenario is then used to design the corresponding optimal heat exchanger network.The latter step, which is based on a multi-period mixed linear programming model, aims at thedesign of a new heat exchanger network topology. In this context, the model includes not only thepossibility to add new heat exchangers but also to shift the preserved heat exchangers for a givenscenario, as long as the original pair of streams is kept. The resulting heat exchanger networksare thus adaptable to every operating conditions identified in the first step of the methodology butalso reconfigurable through the use of by-passes. The performances of the resulting networks areevaluated and classified using key performance indicators, especially the robustness which iscrucial to account for the process variability.The approach was validated on two industrial scale case studies: a MVC production process and arefinery heating train.

[pt] A gestão da cadeia de suprimentos (SCM, Supply Chain Management) está criando oportunidades e desafios para a competição no mundo dos negócios. Apesar disto, ainda existem poucos modelos que oferecem uma análise efetiva de SCM. Dentro deste contexto, esta dissertação tem o intuito de propor um modelo para analisar cadeias de suprimentos baseado em dimensões- chave necessárias para uma bem sucedida SCM. Nessa dissertação, as dimensões consideradas são: integração de processos de negócios, identificação dos membros-chave da cadeia, compartilhamento de informação e medidas de desempenho apropriadas para cadeia de suprimento. Com o objetivo de validar o modelo e avaliar a sua aplicação, foi conduzido um estudo de caso em diferentes cadeias de suprimento de um grande fabricante nacional de cilindros de armazenamento de Gás Natural Veicular (GNV). Para efeitos da análise de SCM, este fabricante é considerado nesta aplicação como a empresa focal da cadeia. A partir da aplicação do modelo nessas diferentes cadeias pôde-se constatar um maior compartilhamento de informação e adoção de medidas de desempenho no processo de negócio SRM (Supplier Relationship Management) do que no processo de negócio CRM (Customer Relationship Management). No CRM, também foi constatado que as cadeias são mais integradas com o fabricante de cilindros de GNV, quando esse cilindro é o seu produto principal, e menos integrada, quando o produto principal das cadeias é outro, como por exemplo, o automóvel zero quilômetro. / [en] The Supply Chain Management (SCM) is creating many opportunities and challenges for world business competition. In spite of this, there are still just a few models that offer an effective SCM analysis. Within this context, this dissertation attempts to propose a model for a supply chain analysis based on key dimensions that are necessary for a successful SCM. The key dimensions considered in this dissertation are: business processes integration, key supply chain members identification, information sharing, and appropriate supply chain performance measures. In order to validate the model and to evaluate its application, a case study was conducted in different supply chains of a big national manufacturer of CNG (Compressed Natural Gas) cylinders for vehicles. Towards the SCM analysis, this manufacturer is considered in this application as the supply chain`s focal company. With the model`s application in these different supply chains, it was possible to figure out a more intense information share and use of performance measures in the SRM (Supplier Relationship Management) business process than in the CRM (Customer Relationship Management) business process. In CRM, it was also found that the supply chains are more integrated with the focal company when the cylinder is the chain`s main product and less integrated when the chain`s main product is another, for instance, a brand new car.