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Resource Efficiency of Processing Plants Vital Source e-bog
Stefan Krämer
(2017)
John Wiley & Sons
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Resource Efficiency of Processing Plants
Monitoring and Improvement
Stefan Krämer og Sebastian Engell
(2018)
Sprog: Engelsk
John Wiley & Sons, Incorporated
2.014,00 kr.
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Detaljer om varen
- 1. Udgave
- Vital Source searchable e-book (Reflowable pages)
- Udgiver: John Wiley & Sons (December 2017)
- ISBN: 9783527804160
This monograph provides foundations, methods, guidelines and examples for monitoring and improving resource efficiency during the operation of processing plants and for improving their design. The measures taken to improve their energy and resource efficiency are strongly influenced by regulations and standards which are covered in Part I of this book. Without changing the actual processing equipment, the way how the processes are operated can have a strong influence on the resource efficiency of the plants and this potential can be exploited with much smaller investments than needed for the introduction of new process technologies. This aspect is the focus of Part II. In Part III we discuss physical changes of the process technology such as heat integration, synthesis and realization of optimal processes, and industrial symbiosis. The last part deals with the people that are needed to make these changes possible and discusses the path towards a resource efficiency culture. Written with industrial solutions in mind, this text will benefit practitioners as well as the academic community.
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Detaljer om varen
- Hardback: 528 sider
- Udgiver: John Wiley & Sons, Incorporated (Maj 2018)
- Forfattere: Stefan Krämer og Sebastian Engell
- ISBN: 9783527340743
This monograph provides foundations, methods, guidelines and examples for monitoring and improving resource efficiency during the operation of processing plants and for improving their design.
The measures taken to improve their energy and resource efficiency are strongly influenced by regulations and standards which are covered in Part I of this book. Without changing the actual processing equipment, the way how the processes are operated can have a strong influence on the resource efficiency of the plants and this potential can be exploited with much smaller investments than needed for the introduction of new process technologies. This aspect is the focus of Part II. In Part III we discuss physical changes of the process technology such as heat integration, synthesis and realization of optimal processes, and industrial symbiosis.
The last part deals with the people that are needed to make these changes possible and discusses the path towards a resource efficiency culture.
Written with industrial solutions in mind, this text will benefit practitioners as well as the academic community.
The measures taken to improve their energy and resource efficiency are strongly influenced by regulations and standards which are covered in Part I of this book. Without changing the actual processing equipment, the way how the processes are operated can have a strong influence on the resource efficiency of the plants and this potential can be exploited with much smaller investments than needed for the introduction of new process technologies. This aspect is the focus of Part II. In Part III we discuss physical changes of the process technology such as heat integration, synthesis and realization of optimal processes, and industrial symbiosis.
The last part deals with the people that are needed to make these changes possible and discusses the path towards a resource efficiency culture.
Written with industrial solutions in mind, this text will benefit practitioners as well as the academic community.
Preface xvii
Part I Resource Efficiency Metrics and Standardised Management Systems 1 1 Energy and Resource Efficiency in the Process Industries 3 Stefan Krämer and Sebastian Engell
1.1 Introduction 3
1.2 Energy and Resources 4
1.2.1 What DoWe Mean by Energy and Resources? 4
1.2.2 Classification of Energy and Resources 5
1.3 Energy and Resource Efficiency 6
1.4 Evaluation of Energy and Resource Efficiency 6
1.5 Evaluation of Energy and Resource Efficiency in Real Time 8
1.6 The Chemical and Process Industry 8
1.6.1 Introduction 8
1.6.2 The Structure of the EU Chemical Industry 9
1.6.3 Energy and Raw Material Use of the Chemical Industry 9
1.7 Recent and Potential Improvements in Energy and Resource Consumption of the Chemical and Process Industries 10
1.8 What Can Be Done to Further Improve the Resource Efficiency of the Process Industry? 11
1.8.1 Make a Plan, Set Targets and Validate the Achievements 11
1.8.2 Measure and Improve Operations 12
1.8.3 Improve the Process 14
1.8.4 Integrate with Other Industrial Sectors and with the Regional Municipal Environment 15
1.8.5 Don''t Forget the People 15
1.9 Conclusions 15 References 16 2 Standards, Regulations and Requirements Concerning Energy and Resource Efficiency 19 Jan U. Lieback, Jochen Buser, David Kroll, Nico Behrendt, and SeánOppermann
2.1 Introducing a Long-Term Development 19
2.1.1 Historical Background and Reasoning 19
2.1.2 Relation of CO2 Emissions and Energy Efficiency 20
2.1.3 EU Goals for Energy Efficiency 21
2.1.4 Energy EfficiencyWorldwide 22
2.1.5 Growing EU Concern on Resource Efficiency 23
2.2 Normative Approaches on Energy and Resource Efficiency 24
2.2.1 Management Systems, Aim and Construction 24
2.2.2 From Precursors towards the ISO 50001 25
2.2.3 Basics of ISO 50001 and Dissemination 26
2.2.4 Energy Efficiency Developments in Germany 27
2.2.5 ISO 50001 and ISO 50004 28
2.2.5.1 ISO 50001 28
2.2.5.2 ISO 50004 28
2.2.6 ISO 50003 and Companions ISO 50006 and 50015 29
2.2.7 EN 16247 and ISO 50002 29
2.2.8 New Standards 31
2.2.9 Normative Approaches Regarding Resource Efficiency 32
2.2.10 Perspectives 33
2.3 Achievements of Energy and Resource Management 34
2.3.1 Energy Baseline (EnB) and Energy Performance Indicators (EnPIs), Controlling Efficiency Improvement 34
2.3.2 Developing EnPIs, Measuring and Verification of Energy Performance 34
2.3.3 Hierarchy of Measures 36
2.3.4 Energy and Resource Efficiency in the Context of Energy Management 36
2.3.5 Examples of Measures 37
2.4 Conclusion 38 References 39 3 Energy and Resource Efficiency Reporting 45 Marjukka Kujanpää, Tiina Pajula, and HelenaWessman-Jääskeläinen
3.1 Executive Summary 45
3.2 Introduction 45
3.3 Obligatory Reporting Mechanisms 47
3.3.1 EU Directive on Industrial Emissions (IED) 47
3.3.2 EU Directive on Non-Financial Reporting 48
3.4 Voluntary Reporting Mechanisms 49
3.4.1 Eco-Management and Audit Scheme (EMAS) 49
3.4.2 OECD Guidelines for Multinational Enterprises 49
3.4.3 UN Global Compact 50
3.4.4 Global Reporting Initiative (GRI) 51
3.4.5 Integrated Reporting and the Framework 52
3.4.6 GHG protocol 54
3.4.7 ISO 14000 Series 54
3.4.8 Environmental Labels 55
3.4.9 Environmental Product Footprint and Organisational Footprint (PEF, OEF) 59
3.5 Other Reporting Mechanisms 59
3.5.1 Key Performance Indicators 59
3.6 Summary of the Energy and Resource Efficiency Reporting Requirements 60 References 61 4 Energy Efficiency Audits 65 GuntherWindecker
4.1 Introduction 65
4.2 Stage
1: Current Energy Status 66
4.3 Stage
2: Basic Analysis 67
4.4 Stage
3: Detailed Analysis and Collection of Ideas 69
4.5 Stage
4: Evaluation and Selection of Measures 72
4.6 Stage
5: Realization and Monitoring 76
4.7 Extension to Resource Efficiency 77
4.8 Closing Remark 77 References 78
Part II Monitoring and Improvement of the Resource Efficiency through Improved Process Operations 79 5 Real-Time Performance Indicators for Energy and Resource Efficiency in Continuous and Batch Processing 81 Benedikt Beisheim,Marc Kalliski, Daniel Ackerschott, Sebastian Engell, and Stefan Krämer
5.1 Introduction 81
5.2 Real-Time Resource Efficiency Indicators 82
5.2.1 Resource Efficiency 82
5.2.2 REI as (Key) Performance Indicators ((K)PI) 83
5.2.3 Real-Time Resource Efficiency Monitoring 84
5.2.4 PrinciplesThat Guide the Definition of Real-Time REI (Adapted from Ref. [10]) 84
5.2.4.1 Gate-to-Gate Approach 85
5.2.4.2 Based on Material and Energy Flow Analysis 85
5.2.4.3 Resource and Output Specific to a Potential for Meaningful Aggregation 85
5.2.4.4 Normalize to the Best Possible Operation 86
5.2.4.5 Consider (Long-Term) Storage Effects 86
5.2.4.6 Include Environmental Impact 86
5.2.4.7 Hierarchy of Indicators - From theWhole Site to a Single Apparatus 87
5.2.4.8 Focus on Technical Performance Independent of Economic Factors 87
5.2.4.9 Extensible to Life-Cycle Analysis (LCA) 87
5.2.5 Extension to LCA and Reporting 87
5.2.6 Real-Time Resource Efficiency Indicators: Generic Indicators 88
5.2.7 Definition of Baselines: Average and Best Cases 88
5.3 Evaluation of the Suitability of Resource Efficiency Indicators 91
5.3.1 Basic Procedure 91
5.3.2 The MORE RACER Evaluation Framework 93
5.3.3 Application of the RACER Framework 95
5.4 Hierarchical Modelling of Continuous Production Complexes 96
5.4.1 Introduction to the Plant Hierarchy 96
5.4.2 Aggregation and Contribution Calculation 98
5.4.2.1 General Performance Deviation 98
5.4.2.2 Aggregation 98
5.4.2.3 Performance Contribution of Lower Levels 99
5.4.2.4 Load Contribution of Lower Levels 100
5.4.2.5 Contribution of Other Factors 101
5.4.2.6 Overall Result 102
5.4.2.7 Illustrative Example 103
5.4.3 Integration of Utility and Energy Provider 105
5.4.4 Product-Oriented REI 106
5.4.5 Simulated Example 107
5.5 Batch Production 112
5.5.1 Batch Resource Efficiency Indicators 113
5.5.1.1 Energy Efficiency 114
5.5.1.2 Material Efficiency 115
5.5.1.3 Water andWaste Efficiency 116
5.5.2 REI for Key Production Phases 116
5.5.2.1 Reaction Efficiency 117
5.5.2.2 Purification Efficiency 117
5.5.3 REI for Plant-Wide Contributions to Resource Efficiency 118
5.5.4 Rules for the Propagation and Aggregation of REI 119
5.5.4.1 Recycled Materials 119
5.5.5 Uniting and Splitting of Batches 119
5.6 Integrated Batch and Continuous Production 122
5.6.1 Transition from Batch to Continuous Production 122
5.6.2 Transition from Continuous to Batch Production 124
5.7 Conclusions 124 Appendix: Decomposition of Î?BDPL 125 References 126 6 Sensing Technology 129 Alejandro Rosales and OonaghMc Nerney
6.1 Introduction 129
6.2 Sensing: General Considerations and Challenges 131
6.2.1 Precision 132
6.2.2 Accuracy 132
6.2.3 The Limitations of Any Measurement Method Due to the Inadequacy of theTheoretical Model for Matching the Real-World Conditions 134
6.2.4 Sampling: The Nature of the Interaction Between the Bodies to be Measured and theMeasurement Instrument is a Key Consideration for Inline Monitoring 135
6.3 Energy Saving by Means of Accurate Metering 136
6.4 Latest Advancements in Spectroscopy Technology for Process-Monitoring-Based Efficiency 137
6.4.1 Introduction and State of the Art 137
6.4.2 Hyperspectral Imaging 138
6.4.3 Time-Gated Raman 139
6.5 Process Analytical Technologies (PAT) 142
6.6 Soft Sensors. Access to the "Truth" Distributed Among a Plurality of Simple Sensors 146
6.7 MEMS-Based Sensors. Smart Sensors 147
6.8 Future Trends in Sensing with Promising Impact on Reliable Process Monitoring 148
6.8.1 Quantum Cascade Lasers (QCLs) 149
6.8.2 Graphene-Based Sensors 150
6.9 European R&D: Driving Forward Sensing Advancements 151
6.10 Conclusion 152 References 154 7 Information Technology and Structuring of Information for Resource Efficiency Analysis and Real-Time Reporting 159 Udo Enste
7.1 Introduction 159
7.2 Information Technology in the Process Industries 159
7.3 Resource Flow Modelling and Structuring of Information 163
7.3.1 Resource Managed Units 163
7.3.2 3-Tier Information Modelling Approach 164
7.4 From Formulae to Runtime Software 167
7.4.1 Recommended System Architecture - Building Context Awareness 167
7.4.2 REI Application Design Process 168
7.5 Industrial Installations 171
7.5.1 Example
1: Batch-Continuous-Process 171
7.5.2 Example
2: Integrated Chemical Production Complex 175
7.6 Summary and Conclusions 178 References 179 8 Data Pre-treatment 181 Cesar de Prada and Daniel Sarabia
8.1 Measurement Errors and Variable Estimation 182
8.2 Data Reconciliation 188
8.3 Gross Errors Detection and Removal 193
8.3.1 StatisticalMethods for Gross Errors Detection 195
8.3.2 Robust M-Estimators 202
8.4
Part I Resource Efficiency Metrics and Standardised Management Systems 1 1 Energy and Resource Efficiency in the Process Industries 3 Stefan Krämer and Sebastian Engell
1.1 Introduction 3
1.2 Energy and Resources 4
1.2.1 What DoWe Mean by Energy and Resources? 4
1.2.2 Classification of Energy and Resources 5
1.3 Energy and Resource Efficiency 6
1.4 Evaluation of Energy and Resource Efficiency 6
1.5 Evaluation of Energy and Resource Efficiency in Real Time 8
1.6 The Chemical and Process Industry 8
1.6.1 Introduction 8
1.6.2 The Structure of the EU Chemical Industry 9
1.6.3 Energy and Raw Material Use of the Chemical Industry 9
1.7 Recent and Potential Improvements in Energy and Resource Consumption of the Chemical and Process Industries 10
1.8 What Can Be Done to Further Improve the Resource Efficiency of the Process Industry? 11
1.8.1 Make a Plan, Set Targets and Validate the Achievements 11
1.8.2 Measure and Improve Operations 12
1.8.3 Improve the Process 14
1.8.4 Integrate with Other Industrial Sectors and with the Regional Municipal Environment 15
1.8.5 Don''t Forget the People 15
1.9 Conclusions 15 References 16 2 Standards, Regulations and Requirements Concerning Energy and Resource Efficiency 19 Jan U. Lieback, Jochen Buser, David Kroll, Nico Behrendt, and SeánOppermann
2.1 Introducing a Long-Term Development 19
2.1.1 Historical Background and Reasoning 19
2.1.2 Relation of CO2 Emissions and Energy Efficiency 20
2.1.3 EU Goals for Energy Efficiency 21
2.1.4 Energy EfficiencyWorldwide 22
2.1.5 Growing EU Concern on Resource Efficiency 23
2.2 Normative Approaches on Energy and Resource Efficiency 24
2.2.1 Management Systems, Aim and Construction 24
2.2.2 From Precursors towards the ISO 50001 25
2.2.3 Basics of ISO 50001 and Dissemination 26
2.2.4 Energy Efficiency Developments in Germany 27
2.2.5 ISO 50001 and ISO 50004 28
2.2.5.1 ISO 50001 28
2.2.5.2 ISO 50004 28
2.2.6 ISO 50003 and Companions ISO 50006 and 50015 29
2.2.7 EN 16247 and ISO 50002 29
2.2.8 New Standards 31
2.2.9 Normative Approaches Regarding Resource Efficiency 32
2.2.10 Perspectives 33
2.3 Achievements of Energy and Resource Management 34
2.3.1 Energy Baseline (EnB) and Energy Performance Indicators (EnPIs), Controlling Efficiency Improvement 34
2.3.2 Developing EnPIs, Measuring and Verification of Energy Performance 34
2.3.3 Hierarchy of Measures 36
2.3.4 Energy and Resource Efficiency in the Context of Energy Management 36
2.3.5 Examples of Measures 37
2.4 Conclusion 38 References 39 3 Energy and Resource Efficiency Reporting 45 Marjukka Kujanpää, Tiina Pajula, and HelenaWessman-Jääskeläinen
3.1 Executive Summary 45
3.2 Introduction 45
3.3 Obligatory Reporting Mechanisms 47
3.3.1 EU Directive on Industrial Emissions (IED) 47
3.3.2 EU Directive on Non-Financial Reporting 48
3.4 Voluntary Reporting Mechanisms 49
3.4.1 Eco-Management and Audit Scheme (EMAS) 49
3.4.2 OECD Guidelines for Multinational Enterprises 49
3.4.3 UN Global Compact 50
3.4.4 Global Reporting Initiative (GRI) 51
3.4.5 Integrated Reporting and the Framework 52
3.4.6 GHG protocol 54
3.4.7 ISO 14000 Series 54
3.4.8 Environmental Labels 55
3.4.9 Environmental Product Footprint and Organisational Footprint (PEF, OEF) 59
3.5 Other Reporting Mechanisms 59
3.5.1 Key Performance Indicators 59
3.6 Summary of the Energy and Resource Efficiency Reporting Requirements 60 References 61 4 Energy Efficiency Audits 65 GuntherWindecker
4.1 Introduction 65
4.2 Stage
1: Current Energy Status 66
4.3 Stage
2: Basic Analysis 67
4.4 Stage
3: Detailed Analysis and Collection of Ideas 69
4.5 Stage
4: Evaluation and Selection of Measures 72
4.6 Stage
5: Realization and Monitoring 76
4.7 Extension to Resource Efficiency 77
4.8 Closing Remark 77 References 78
Part II Monitoring and Improvement of the Resource Efficiency through Improved Process Operations 79 5 Real-Time Performance Indicators for Energy and Resource Efficiency in Continuous and Batch Processing 81 Benedikt Beisheim,Marc Kalliski, Daniel Ackerschott, Sebastian Engell, and Stefan Krämer
5.1 Introduction 81
5.2 Real-Time Resource Efficiency Indicators 82
5.2.1 Resource Efficiency 82
5.2.2 REI as (Key) Performance Indicators ((K)PI) 83
5.2.3 Real-Time Resource Efficiency Monitoring 84
5.2.4 PrinciplesThat Guide the Definition of Real-Time REI (Adapted from Ref. [10]) 84
5.2.4.1 Gate-to-Gate Approach 85
5.2.4.2 Based on Material and Energy Flow Analysis 85
5.2.4.3 Resource and Output Specific to a Potential for Meaningful Aggregation 85
5.2.4.4 Normalize to the Best Possible Operation 86
5.2.4.5 Consider (Long-Term) Storage Effects 86
5.2.4.6 Include Environmental Impact 86
5.2.4.7 Hierarchy of Indicators - From theWhole Site to a Single Apparatus 87
5.2.4.8 Focus on Technical Performance Independent of Economic Factors 87
5.2.4.9 Extensible to Life-Cycle Analysis (LCA) 87
5.2.5 Extension to LCA and Reporting 87
5.2.6 Real-Time Resource Efficiency Indicators: Generic Indicators 88
5.2.7 Definition of Baselines: Average and Best Cases 88
5.3 Evaluation of the Suitability of Resource Efficiency Indicators 91
5.3.1 Basic Procedure 91
5.3.2 The MORE RACER Evaluation Framework 93
5.3.3 Application of the RACER Framework 95
5.4 Hierarchical Modelling of Continuous Production Complexes 96
5.4.1 Introduction to the Plant Hierarchy 96
5.4.2 Aggregation and Contribution Calculation 98
5.4.2.1 General Performance Deviation 98
5.4.2.2 Aggregation 98
5.4.2.3 Performance Contribution of Lower Levels 99
5.4.2.4 Load Contribution of Lower Levels 100
5.4.2.5 Contribution of Other Factors 101
5.4.2.6 Overall Result 102
5.4.2.7 Illustrative Example 103
5.4.3 Integration of Utility and Energy Provider 105
5.4.4 Product-Oriented REI 106
5.4.5 Simulated Example 107
5.5 Batch Production 112
5.5.1 Batch Resource Efficiency Indicators 113
5.5.1.1 Energy Efficiency 114
5.5.1.2 Material Efficiency 115
5.5.1.3 Water andWaste Efficiency 116
5.5.2 REI for Key Production Phases 116
5.5.2.1 Reaction Efficiency 117
5.5.2.2 Purification Efficiency 117
5.5.3 REI for Plant-Wide Contributions to Resource Efficiency 118
5.5.4 Rules for the Propagation and Aggregation of REI 119
5.5.4.1 Recycled Materials 119
5.5.5 Uniting and Splitting of Batches 119
5.6 Integrated Batch and Continuous Production 122
5.6.1 Transition from Batch to Continuous Production 122
5.6.2 Transition from Continuous to Batch Production 124
5.7 Conclusions 124 Appendix: Decomposition of Î?BDPL 125 References 126 6 Sensing Technology 129 Alejandro Rosales and OonaghMc Nerney
6.1 Introduction 129
6.2 Sensing: General Considerations and Challenges 131
6.2.1 Precision 132
6.2.2 Accuracy 132
6.2.3 The Limitations of Any Measurement Method Due to the Inadequacy of theTheoretical Model for Matching the Real-World Conditions 134
6.2.4 Sampling: The Nature of the Interaction Between the Bodies to be Measured and theMeasurement Instrument is a Key Consideration for Inline Monitoring 135
6.3 Energy Saving by Means of Accurate Metering 136
6.4 Latest Advancements in Spectroscopy Technology for Process-Monitoring-Based Efficiency 137
6.4.1 Introduction and State of the Art 137
6.4.2 Hyperspectral Imaging 138
6.4.3 Time-Gated Raman 139
6.5 Process Analytical Technologies (PAT) 142
6.6 Soft Sensors. Access to the "Truth" Distributed Among a Plurality of Simple Sensors 146
6.7 MEMS-Based Sensors. Smart Sensors 147
6.8 Future Trends in Sensing with Promising Impact on Reliable Process Monitoring 148
6.8.1 Quantum Cascade Lasers (QCLs) 149
6.8.2 Graphene-Based Sensors 150
6.9 European R&D: Driving Forward Sensing Advancements 151
6.10 Conclusion 152 References 154 7 Information Technology and Structuring of Information for Resource Efficiency Analysis and Real-Time Reporting 159 Udo Enste
7.1 Introduction 159
7.2 Information Technology in the Process Industries 159
7.3 Resource Flow Modelling and Structuring of Information 163
7.3.1 Resource Managed Units 163
7.3.2 3-Tier Information Modelling Approach 164
7.4 From Formulae to Runtime Software 167
7.4.1 Recommended System Architecture - Building Context Awareness 167
7.4.2 REI Application Design Process 168
7.5 Industrial Installations 171
7.5.1 Example
1: Batch-Continuous-Process 171
7.5.2 Example
2: Integrated Chemical Production Complex 175
7.6 Summary and Conclusions 178 References 179 8 Data Pre-treatment 181 Cesar de Prada and Daniel Sarabia
8.1 Measurement Errors and Variable Estimation 182
8.2 Data Reconciliation 188
8.3 Gross Errors Detection and Removal 193
8.3.1 StatisticalMethods for Gross Errors Detection 195
8.3.2 Robust M-Estimators 202
8.4
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