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Improved Manufacturing Operations

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Title: Improved Manufacturing Operations


1
CHAPTER 5
  • Improved Manufacturing Operations

2
Cost Benefit Analysis
3
A Typical Industrial Process
4
Elements of P2 Efforts by 212 Industries
5
The Manufacturing Process
  • Objective
  • to transform an idea into a saleable product
  • Steps
  • Design
  • Product Development
  • Quality Control
  • General Management
  • Production

6
Design
  • Product Planning
  • long term process to identify the product areas
    of interest
  • Product Development
  • concept further explored in relation to
    possibilities of the company
  • Product Design
  • creates a design on the basis of market-related,
    functional technical, manufacturing and
    aesthetics requirements

7
Sequential Engineering
  • Marketing identifies the need for new products,
    price ranges and their expected performance from
    customers or potential customers
  • Design and Engineering work independently and
    develop the technical requirements and final
    design details
  • Manufacturing, testing, quality control and
    service groups see the design in an almost
    complete stage
  • As the manufacturing process is sequential in
    progression, it is commonly called sequential
    engineering

8
Sequential Engineering Process
9
Structure Of An Industrial Enterprise
10
Concurrent Engineering
  • Provides a systematic and integrated approach to
    introduction and design of products so as to
    ensure that decisions made in the design stage
    result in a minimum overall cost during its
    life-cycle

11
Concurrent Engineering Process
12
Concurrent Engineering (contd.)
  • Objective
  • Decreased product development lead time
  • Improved profitability
  • Greater competitiveness
  • Greater control of design and manufacturing costs
  • Close integration between departments
  • Enhanced reputation of the company and its
    products
  • Improved product quality
  • Promotion of team spirit

13
Concurrent Engineering (contd.)
  • Design for Manufacture
  • consideration of how well a design can be
    integrated into factory processes such as
    fabrication and assembly
  • Design for Assembly
  • consideration of ease of assembly, error-free
    assembly, common part assembly, etc.
  • Design for Serviceability
  • design to facilitate initial installation, as
    well as repair and modification of products in
    the field

14
Concurrent Engineering (contd.)
  • Design for Reliability
  • consideration of topics such as electrostatic
    discharge, corrosion resistance, and operation
    under variable ambient conditions and so on
  • Design for X
  • term coined to describe these various segments,
    where X stands for the particular segment

15
Chemical Reactors
  • place where raw materials are converted into
    products
  • primary source of waste materials
  • operate in batch or continuous mode
  • Batch mode all reagents are added to a stirred
    tank at the beginning of the reaction, no new
    material is fed or removed during the reaction
    period
  • Continuous flow reagents are continually fed and
    products are continually removed

16
Rate of Conversion
17
Continuous Flow Reactors
18
Heat Exchangers
  • commonly used to exchange heat between products
    and reactants
  • can be heater or cooler
  • direct and indirect type
  • indirect shell and tube exchangers

19
Distillation
  • most important process for the separation of
    chemical mixtures
  • compounds with different vapor pressures cane be
    separated from a mixture by gradually varying the
    temperature
  • batch or continuous

20
Distillation Columns
21
Absorption
  • chemical or physical process of selective
    transfer of one or more compounds in the process
    stream into a liquid
  • different types packed, tray, spray towers
  • countercurrent or co-current

22
Adsorption
  • chemical or physical binding with the contact
    surface
  • usually carried out in a column
  • e.g. activated carbon, activated silica, resins

23
Extraction
  • transfer of solutes from a liquid or solid phase
    into a liquid solvent
  • both liquid-liquid and solid-liquid extraction
    possible
  • supercritical extraction
  • essentially a liquid extraction process employing
    compressed fluids under supercritical extraction
    instead of normal solvents

24
Supercritical Point
25
Supercritical Fluid Properties
26
Drying
  • used to either recover a solvent or to remove
    water or solvents from a solid product
  • batch or continuous basis
  • different types tunnel, rotary, drum, spray,
    flash evaporators

27
Process Development And Design
  • Refinement of a process concept from early
    conceptual stages through preliminary engineering
  • Waste generation can often be minimized through
    proper design and operation of the process system

28
Separation Technologies
29
Typical Environmental Design Constraints and
Objectives
30
P2 Potential in theDesign Process
31
Computer Tools
  • assist in the preliminary stages of design, such
    as molecular description, synthesis pathway
    identification, etc.
  • assist in design phases
  • currently, computers are used in every stage of
    manufacturing, from conceptual design to final
    manufacturing.

32
Computer Based ToolsIndustrial-scale Process
Design
33
Computer Based ToolsChemical Changes
34
Computer Based ToolsIndustrial Production Stage
35
The Clean Process Advisory System
  • collaborative effort of CenCITT, CWRT, and NCMS
  • furnishes engineers with a means to routinely
    find, simulate and compare various design
    approaches on the basis of P2
  • technology descriptions and expert guidance to
    find design options
  • numerical simulations and property data resources
    to simulate those options, and
  • data resources and algorithms to quantify and
    compare their pollution prevention dividends in
    conjunction with cost and safety implications

36
Strategic WAste Minimization Initiative
  • SWAMI developed by USEPA
  • Designed to identify waste minimization
    opportunities within industrial settings
  • provides a scheme for identifying and
    prioritizing (on a cost or volume basis) waste
    reduction opportunities
  • performs mass balance calculations, draws process
    flow diagrams, and
  • directs the selection of candidate waste
    minimization strategies.

37
EcoSys
  • Developed by DoE
  • allows the opportunity to see the potential
    impact of environmental strategies, manufacturing
    processes or products before investing
    significant amounts of time or money
  • includes a database with the environmental
    characteristics of more than 500 substances and
    four models of environmental thinking

38
Process ChangesAdvanced Process Technologies
  • Question can anything be done to increase the
    efficiency of the reaction?
  • Many times, simple changes in operating
    conditions like reaction temperature or process
    can greatly increase efficiency

39
Strategies for Minimizing Pollution
  • Avoid adsorptive separations where adsorbent beds
    cannot be readily regenerated
  • Provide separate reactors for recycle streams, to
    permit optimization of reactions
  • Consider low-temperature distillation columns
    when dealing with thermally labile process
    streams
  • Consider high-efficiency packing rather than
    conventional tray-type columns, thus reducing
    pressure drop and decreasing reboiler temperatures

40
Strategies for Minimizing Pollution (contd.)
  • Consider continuous processing when batch
    cleaning wastes are likely to be significant
    (e.g., with highly viscous, water-insoluble, or
    adherent materials)
  • Consider scraped-wall exchangers and evaporators
    with viscous materials to avoid thermal
    degradation of product

41
Process ChangesImproved Reactor Design
  • Improve the degree of agitation
  • better mass transfer efficiency
  • use more efficient mixers and baffling systems
  • Insulate the reactors
  • improves temperature control within the reactor
  • Use high efficiency heat exchangers
  • Switch to continuous flow mode
  • Simplify cleaning of the reactor

42
Other Process Changes
  • Increasing the number of stages in extraction
    processes that use water
  • Using spray balls as a scouring agent for more
    effective internal vessel cleaning
  • Changing from wet cooling towers to air coolers
  • Improving control of cooling tower blowdown
  • Attaching triggers to hoses to prevent unattended
    running

43
Other Process Changes (contd.)
  • Improving energy efficiency to reduce steam
    demand and hence reduce the wastewater generated
    by the steam system through boiler blowdown,
    aqueous waste from boiler feedwater equipment,
    and condensate loss
  • Increasing condensate return from steam lines to
    reduce boiler blowdown and aqueous waste from
    boiler feedwater equipment
  • Improving control of boiler blowdown

44
Process ChangesImproved Reactor Control
  • Improving reactor environment controls can have a
    substantial impact
  • Control system efficiency improved by
  • Measurement accuracy, stability and repeatability
  • Sensor locations, controller response action
  • Process dynamics
  • Final control element (valves, dampers, relays,
    etc.) characteristics and location
  • Overall system reliability

45
Process ChangesImproved Separation Processes
  • Do mechanical separations first if more than one
    phase exists in the feed.
  • Avoid over-design and use designs that operate
    efficiently over a range of conditions. Favor
    simple processes.
  • Favor processes transferring the minor rather
    than the major component between phases.
  • Favor high separation factors.
  • Recognize value differences of energy in
    different forms and of heat and cold at different
    temperature levels.

46
Process ChangesImproved Separation
Processes(Contd.)
  • Investigate use of heat pump, vapor compression,
    or multi-effects for separation with small
    temperature ranges.
  • Use staging or countercurrent flow where
    appropriate.
  • For similar separation factors, favor energy
    driven processes over mass separating-agent
    processes.
  • For energy driven processes, favor those with
    lower heat of phase change.

47
Separation Processes
48
Recycling
  • Attractive way of reducing waste streams needing
    treatment and the associated costs, while at the
    same time reducing the demand for virgin process
    chemicals and their associated costs
  • May be on-site or off-site

49
Recycling Options
50
Typical Water Use on a Chemical Process Site
51
Product Changes
  • Make changes in the product itself or in the
    chemicals used to make the product
  • Replace solvent-based paints with water-base
    paints
  • Substitute parts which can be reused
  • Workpieces with fewer turnings and cavities will
    reduce the amount of dragout from process tanks

52
Storage
  • Establish a Spill Prevention, Control and
    Countermeasures (SPCC) plan
  • Use properly designed storage tanks and vessels,
    and only for the intended purpose
  • Install overflow alarms on all storage tanks
  • Install secondary containment areas
  • Document all spillage
  • Space containers to facilitate inspection
  • Stack containers properly to minimize tipping,
    breaking, or puncturing

53
Storage (contd.)
  • Raise containers off the floor to minimize
    corrosion from sweating concrete
  • Separate different hazardous substances to
    minimize cross-contamination and to separate
    incompatible materials
  • Use a just-in-time order system for process
    chemicals
  • Order reagent chemicals in exact amounts
  • Establish an inventory control program to trace
    chemicals from cradle to grave
  • Rotate chemical stock

54
Storage (contd.)
  • Validate shelf-life of chemical expiration dates,
    eliminate shelf-life requirements for stable
    materials, and test effectiveness of outdated
    materials
  • Label all materials and containers with material
    identification, health hazards, and first aid
    recommendations
  • Switch to less hazardous raw materials
  • Switch to materials packaging and storage
    containers that are less susceptible to corrosion
    or leakage

55
Storage (contd.)
  • Use large containers where possible to minimize
    the tank surface-to-volume ratio, thereby
    reducing the area that has to be cleaned
  • Use rinsable/reusable containers
  • Empty drums and containers thoroughly before
    cleaning or disposing

56
Most Common Deficiencies in Storing Hazardous
Wastes and Materials
57
Management
  • For P2 programs to be successful, management has
    to be fully committed to concepts of Pollution
    Prevention
  • Well conceived and functional preventive
    maintenance program
  • Proper employee training
  • Good Record keeping

58
Housekeeping
  • Close or cover solvent containers when not in use
  • Isolate liquid wastes from solid wastes
  • Turn off equipment and lights when not in use
  • Eliminate leaks, drips and other fugitive
    emissions
  • Control and clean up all spills and leaks as they
    occur
  • Develop a preventive maintenance schedule and
    enforce its use
  • Schedule production runs to minimize cleaning
    frequency

59
Housekeeping (contd.)
  • Improve lubrication of equipment
  • Keep machinery running at optimum efficiency
  • Dry sweep floors when ever possible
  • Do not allow materials to mix in common floor
    drains
  • Insist on proper labeling of all containers
  • Educate all employees as to the need for proper
    housekeeping practices
  • Include housekeeping reviews in all process
    inspections
  • Adopt a Total Quality Management philosophy

60
Training
  • Key to the success of any P2 program
  • Should be ongoing, with frequent review updates
  • Should provide the necessary information to
    achieve P2 goals
  • Variety of training techniques should be used
  • Operators should play a major role in training

61
Training(contd.)
  • Promote awareness of waste reduction initiatives
  • Establish quantifiable wastewater reduction goals
  • Train personnel in waste reduction techniques and
    water usage minimization practices
  • Implement plant-wide waste reduction techniques
    and water usage minimization practices
  • Monitor progress toward attaining waste reduction
    goals and readjust objectives if they prove to be
    unattainable
  • Attain waste reduction goals

62
Record Keeping
  • Helps in both the development and implementation
    of a sound pollution prevention program
  • Document process procedures, control parameters,
    chemical specifications, chemical usage, energy
    usage, waste generation, and spill frequencies
  • Inventory control, for both process chemicals and
    waste materials, will reduce the volumes and thus
    reduce costs and potential losses to the
    environment from leaks or spills, or the need to
    dispose of contaminated, off-specification or
    out-of-date reagents
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