Process industry

This paper illustrates the status of lean manufacturing adoption in Indian process industries. Paper discusses the findings of a comprehensive survey of 120 Indian process industries and explores the level of adoption of lean in Indian process industries in terms of adoption of lean practices, reasons of lean implementation, challenges to implement lean and benefits of implementing lean in Indian process industries.

"Background: Chemical industries and facilities pose the risk of potential hazards in case of accidents, which lead to injuries and financial losses due to the spread of materials in the surroundings of the accident. These materials often have harmful properties (e.g., toxicity or flammability), and their release could cause secondary accidents (e.g., fire, poisoning, and explosion). The present study aimed to assess the effects of toxic sulfur dioxide (SO2) in a suffocation unit.
Methods: A possible scenario of SO2 emission was selected using the matrix presented by the researchers. Afterwards, the hazard and operability study method was used to analyze the conditions. The modeling and evaluation of the outcomes of the selected scenario for SO2 gas emission from the gas pipeline were carried out using the PHAST7.11 software.
Results: The worst scenario was observed in the employees within the approximate distance of 10 meters and height of two meters from the gas leakage (100 mm leakage diameter) and gas diffusion angled from horizontal impingement.
Conclusion: About 1.84 seconds after the leakage of toxic SO2 (distance: 10 meters, height: 1.39 m), the concentration was approximately 39,339 ppm, which was the worst scenario in August, with the possible mortality risk of 49%."

ln this report the physicochemical principles of deposition and fouling of heavy organics and other compounds are presented and discussed. The basic requirements for predictive modelling and mitigation of fouling in industrial processes are presented. The possible mechanisms of fouling in various processes are discussed in light of the general principles of fouling known and the available industrial processes fouling data. The various stages of fouling and the fouling prediction modelling requirements for those stages in industrial processes are specified and the data requirements for each stage are presented. Parameters influencing the fouling are specified and the foundations for predictive modelling, which will help to mitigate fouling and increase the useful life of processes, are specified.

Confronted with the competitive challenges brought by the ongoing digitization of the industrial sector --Industry 4.0, plant owners and contractors in the process industry are called to create and exploit digital plant models enabling the efficient execution and integration of different activities across the entire plant lifecycle. In the case of existing process facilities, an important part of the information required for this task exists already in form of legacy engineering documents, such as scanned diagrams and schematics in elementary digital formats. However, current engineering and enterprise tools cannot fully exploit this source of knowledge due to the non-computer-interpretable nature and heterogeneity of such data sources. As a consequence, process experts and engineers must often retrieve and consolidate information manually when executing daily activities; a practice that is not only error prone but also time-intensive, and costly. In an effort to cope with that problem, this thesis presents a functional methodology for the capture, formalization, integration, and subsequent exploitation of legacy design documents, specifically Piping and Instrumentation Diagrams, and Control Logic Diagrams. Motivated by the concept Automation of Automation, the proposed methodology aims to serve as a basis for the automatic execution of required steps within automation-related plant modernization and operational tasks. Experimental results demonstrate the effective applicability of the approach in two use cases of industrial relevance: (a) automatic generation of plant simulation models for the validation of basic control functions during plant modernization projects, and (b) fault propagation analysis for supporting alarm management and fault diagnosis during plant operation.

Boiler is a typically complex system which is multi-input, multi-output, nonlinear as well as non-self-balanced, and boiler combustion of power station is complex physical and chemical process. The efficiency of a boiler system is important in several ways. Thus this work will provide the performance comparison of Briquette Boiler & Furnace Boiler of process industry and the ways to improve its efficiency. The company is using a basic rankine cycle with an open system. The source of raw water for boiler is pumped from the bore wells provided by HSIIDC to the reserve pond for further internal and external treatments. These approaches are by increasing pressure, by increasing temperature and by increasing both parameters up to certain limit. The results show that the use of increase pressure and temperature can improve boiler efficiency as well as the plant efficiency as compared to other methods.