Process Industries 2

As a result of knowledge exchange between the academic and industrial worlds, this book analyzes the process industries impacted by the digital revolution that accompanies the ongoing energy and environmental transitions. Process Industries 2 first discusses bio-industries and analyzes the development of products of microbial origin. It then studies all the stages of industrialization that facilitate the progress from research to the production of a finished product, as well as industrial management techniques. Using concrete examples, this book presents the instruments of the digital revolution (artificial intelligence, virtual reality, augmented reality, the Internet of Things, digital twins), while analyzing their impact on the supply chain and operators. Boxes within the book, written by recognized specialists, invite both students and professionals, who are faced with a changing world, to reflect on the industry and the world of tomorrow.

Industrial Process Identification and Control Design is devoted to advanced identification and control methods for the operation of continuous-time processes both with and without time delay, in industrial and chemical engineering practice. The simple and practical step- or relay-feedback test is employed when applying the proposed identification techniques, which are classified in terms of common industrial process type: open-loop stable; integrating; and unstable, respectively. Correspondingly, control system design and tuning models that follow are presented for single-input-single-output processes. Furthermore, new two-degree-of-freedom control strategies and cascade control system design methods are explored with reference to independently-improving, set-point tracking and load disturbance rejection. Decoupling, multi-loop, and decentralized control techniques for the operation of multiple-input-multiple-output processes are also detailed. Perfect tracking of a desire output trajectory is realized using iterative learning control in uncertain industrial batch processes. All the proposed methods are presented in an easy-to-follow style, illustrated by examples and practical applications. This book will be valuable for researchers in system identification and control theory, and will also be of interest to graduate control students from process, chemical, and electrical engineering backgrounds and to practising control engineers in the process industry.

Compared to its widespread implementation across almost all areas of production, Lean improvement efforts lag within the process industries. While many innovators have successfully applied Lean principles to these industries during the past three decades, most of those pioneering efforts were never recorded to guide the improvement efforts of others. Drawing on more than 40 years of application experience at one of the world’s largest chemical and materials manufacturers, coupled with 10 years in private practice, Peter King corrects this void by providing the first comprehensive resource written explicitly for change agents within the process industries. Focusing on areas where the improvement needs of the process industry differ from parts assembly manufacturing, Lean for the Process Industries: Dealing with Complexity, Second Edition: Covers each of the eight wastes commonly described in Lean literature, looking at how they manifest themselves in process operations. Explains how to adapt value stream mapping for process operations. Shows how to identify the root causes of bottlenecks, and how to manage them to optimize flow until they can be eliminated. Provides practical techniques to overcome the barriers which have prevented the application of Cellular Manufacturing to process operations. Discusses the role of business leadership in a Lean strategy, describing both enabling and counter-productive management behaviors Since the publication of the first edition of this book, Peter King has been busy consulting with food, beverage, gasoline additive, and nutraceutical companies -- these new experiences have broadened his perspectives on certain Lean processes and have given him a richer set of examples to discuss in this new edition. While Value Stream Mapping is a very powerful tool to understand flow, bottlenecks, and waste in an operation, the traditional format as presented in many other books does not describe all of the data required to fully understand process flow and its detractors. This new edition highlights the necessary additions with examples of why they are useful. Product wheel scheduling achieves production leveling in a far more comprehensive and effective way than traditional heijunka methods. This edition has a more thorough description of the wheel concept and design steps, and more examples from actual applications.

This volume is a valuable reference work for the student and the practising engineer in the chemical, pharmaceutical, minerals, food, plastics, paper and metallurgical industries. The second edition of this successful text has been thoroughly rewritten and updated. Based on the long running post-experience course produced by the University of Bradford, in association with the Institution of Chemical Engineers, it covers all aspects of mixing, from fundamentals through to design procedures in single and multi-phase systems. Experts from both industry and academia have contributed to this work giving both a theoretical practical approach. It covers dry and wet powders, single and two-phase liquids, solid/liquid and gas/liquid systems. The range of mixers available for such diverse duties is dealt with, including tumbler mixers for powders, mechanically agitated vessels, in-line continuous mixers and jet mixers. Coverage is given of the range of mixing objectives, varying from achieving product uniformity to obtaining optimum conditions for mass transfer and chemical reactions. This volume is a valuable reference work for the student and the practising engineer in the chemical, pharmaceutical, minerals, food, plastics, paper and metallurgical industries. The second edition of this successful text has been thoroughly rewritten and updated. Based on the long running post-experience course produced by the University of Bradford, in association with the Institution of Chemical Engineers, it covers all aspects of mixing, from fundamentals through to design procedures in single and multi-phase systems. Experts from both industry and academia have contributed to this work giving both a theoretical practical approach. It covers dry and wet powders, single and two-phase liquids, solid/liquid and gas/liquid systems. The range of mixers available for such diverse duties is dealt with, including tumbler mixers for powders, mechanically agitated vessels, in-line continuous mixers and jet mixers. Coverage is given of the range of mixing objectives, varying from achieving product uniformity to obtaining optimum conditions for mass transfer and chemical reactions.

Domino Effects in the Process Industries discusses state-of-the-art theories, conceptual models, insights and practical issues surrounding large-scale knock-on accidents—so-called domino effects—in the chemical and process industries. The book treats such extremely low-frequency phenomena from a technological perspective, studying possible causes and introducing several approaches to assess and control the risks of these scenarios. The authors also examine these events from a managerial viewpoint, discussing single and multi-plant management insights and requirements to take pro-active measures to prevent such events. Academics, regulators, and industrialists who study and analyze domino effects in order to prevent such events will find the book unique and highly valuable. Outlines available methods in analyzing these events, aiding understanding of the accidents and their causes Covers current modelling, control and management tactics of domino effects, -facilitating prevention Identifies areas where new research is needed

As a result of knowledge exchange between the academic and industrial worlds, this book analyzes the process industries impacted by the digital revolution that accompanies the ongoing energy and environmental transitions. Process Industries 2 first discusses bio-industries and analyzes the development of products of microbial origin. It then studies all the stages of industrialization that facilitate the progress from research to the production of a finished product, as well as industrial management techniques. Using concrete examples, this book presents the instruments of the digital revolution (artificial intelligence, virtual reality, augmented reality, the Internet of Things, digital twins), while analyzing their impact on the supply chain and operators. Boxes within the book, written by recognized specialists, invite both students and professionals, who are faced with a changing world, to reflect on the industry and the world of tomorrow.