Process Engineering and Industrial Management

ISBN-13: 9781848213265 / Angielski / Twarda / 2012 / 520 str.

J Dal Pont

Opis

Process Engineering, the science and art of transforming raw materials and energy into a vast array of commercial materials, was conceived at the end of the 19th Century. Its history in the role of the Process Industries has been quite honorable, and techniques and products have contributed to improve health, welfare and quality of life. Today, industrial enterprises, which are still a major source of wealth, have to deal with new challenges in a global world. They need to reconsider their strategy taking into account environmental constraints, social requirements, profit, competition, and resource depletion.
-Systems thinking- is a prerequisite from process development at the lab level to good project management. New manufacturing concepts have to be considered, taking into account LCA, supply chain management, recycling, plant flexibility, continuous development, process intensification and innovation.
This book combines experience from academia and industry in the field of industrialization, i.e. in all processes involved in the conversion of research into successful operations. Enterprises are facing major challenges in a world of fierce competition and globalization. Process engineering techniques provide Process Industries with the necessary tools to cope with these issues. The chapters of this book give a new approach to the management of technology, projects and manufacturing. Contents Part 1: The Company as of Today
1. The Industrial Company: its Purpose, History, Context, and its Tomorrow?, Jean-Pierre Dal Pont.
2. The Two Modes of Operation of the Company - Operational and Entrepreneurial, Jean-Pierre Dal Pont.
3. The Strategic Management of the Company: Industrial Aspects, Jean-Pierre Dal Pont.
Part 2: Process Development and Industrialization
4. Chemical Engineering and Process Engineering, Jean-Pierre Dal Pont.
5. Foundations of Process Industrialization, Jean-Francois Joly.
6. The Industrialization Process: Preliminary Projects, Jean-Pierre Dal Pont and Michel Royer.
7. Lifecycle Analysis and Eco-Design: Innovation Tools for Sustainable Industrial Chemistry, Sylvain Caillol.
8. Methods for Design and Evaluation of Sustainable Processes and Industrial Systems, Catherine Azzaro-Pantel.
9. Project Management Techniques: Engineering, Jean-Pierre Dal Pont.
Part 3: The Necessary Adaptation of the Company for the Future
10. Japanese Methods, Jean-Pierre Dal Pont.
11. Innovation in Chemical Engineering Industries, Oliver Potier and Mauricio Camargo.
12. The Place of Intensified Processes in the Plant of the Future, Laurent Falk.
13. Change Management, Jean-Pierre Dal Pont.
14. The Plant of the Future, Jean-Pierre Dal Pont.

Spis treści

Foreword xv
Richard DARTON

Foreword xvii
Jean PELIN

Introduction xix
Jean–Pierre DAL PONT

Acknowledgments xxv

PART 1: THE COMPANY AS OF TODAY 1

Chapter 1. The Industrial Company: its Purpose, History, Context, and its Tomorrow? 3
Jean–Pierre DAL PONT

1.1. Purpose, structure, typology 4

1.2. A centennial history 8

1.3. New challenges imposed by globalization and sustainable development 24

1.4. Our planet 32

1.5. The company of tomorrow. Some thoughts 45

1.6. Bibliography 49

Chapter 2. The Two Modes of Operation of the Company Operational and Entrepreneurial 51
Jean–Pierre DAL PONT

2.1. Operational mode 53

2.2. Entrepreneurial mode, project management the operational/entrepreneurial conflict 96

2.3. Bibliography 99

Chapter 3. The Strategic Management of the Company: Industrial Aspects 101
Jean–Pierre DAL PONT

3.1. Systemic view of the industrial company 102

3.2. Strategy and strategic analysis of the company 103

3.3. Development of the strategic plan: its deliverables 107

3.4. Technological choices and vocations 108

3.5. Bibliography 111

PART 2: PROCESS DEVELOPMENT AND INDUSTRIALIZATION 113

Chapter 4. Chemical Engineering and Process Engineering 115
Jean–Pierre DAL PONT

4.1. History of chemical engineering and process engineering 115

4.2. Process engineering 119

4.3. The chemical reactor 121

4.4. Bioreactors 126

4.5. Transportation and transfers 129

4.6. Unit operations 131

4.7. Separation processes: process engineering and the new challenges for life sciences 141

4.8. Acknowledgments 144

4.9. Bibliography 145

Chapter 5. Foundations of Process Industrialization 147
Jean–François JOLY

5.1. Introduction 147

5.2. The various stages of process development: from research to the foundations of industrialization 148

5.3. The pre–study (or pre–development process) 149

5.4. Development stage of the process 157

5.5. General conclusion 184

5.6. Bibliography 186

5.7. List of acronyms 188

Chapter 6. The Industrialization Process: Preliminary Projects 189
Jean–Pierre DAL PONT and Michel ROYER

6.1. Steps of industrialization 192

6.2. Bases of industrialization or process development 193

6.3. Feasibility study 194

6.4. Cost and typical duration of industrialization studies 198

6.5. Content of an industrialization project conceptual engineering 199

6.6. Typical organization of an industrialization project 201

6.7. Business/industrial interface 202

6.8. Typology of industrialization projects 204

6.9. The industrial preliminary projects 205

6.10. Selection of production sites 209

6.11. The consideration of sustainability in the preliminary projects 210

6.12. Tips for conducting preliminary projects 215

6.13. Modification of the project scope 222

6.14. Host site 223

6.15. Reporting 228

6.16. Bibliography 232

Chapter 7. Lifecycle Analysis and Eco–Design: Innovation Tools for Sustainable Industrial Chemistry 233
Sylvain CAILLOL

7.1. Contextual elements 233

7.2. The chemical industry mobilized against upheavals 237

7.3. The lifecycle analysis, an eco–design tool definitions and concepts 243

7.4. Innovation through eco–design 258

7.5. Limits of the tool 267

7.6. Conclusion: the future of eco–design 271

7.7. Bibliography 273

Chapter 8. Methods for Design and Evaluation of Sustainable Processes and Industrial Systems 275
Catherine AZZARO–PANTEL

8.1. Introduction 275

8.2. AIChE and IChemE metrics 279

8.3. Potential environmental impact index (waste reduction algorithm) 286

8.4. SPI (Sustainable Process Index) 292

8.5. Exergy as a thermodynamic base for a sustainable development metrics 294

8.6. Indicators resulting from a lifecycle assessment 294

8.7. Process design methods and sustainable systems 297

8.8. Conclusion 299

8.9. Bibliography 301

Chapter 9. Project Management Techniques: Engineering 307
Jean–Pierre DAL PONT

9.1. Engineer and engineering 307

9.2. Project organization 310

9.3. Management tools for industrial projects 314

9.4. The engineering project: from Process Engineering to the start of the facility 331

9.5. The amount of investment 346

9.6. Profitability on investment [DOR 81, MIK 10] 350

9.7. Conclusion 353

9.8. Bibliography 353

PART 3: THE NECESSARY ADAPTATION OF THE COMPANY FOR THE FUTURE 355

Chapter 10. Japanese Methods 357
Jean–Pierre DAL PONT

10.1. Japan from the Meiji era to now. The origin of the Japanese miracle 357

10.2. W.E. Deming and Japan 359

10.3. The Toyoda family Taiichi Ohno The Toyota Empire 362

10.4. Toyotism 363

10.5. The American response 368

10.6. Bibliography 369

Chapter 11. Innovation in Chemical Engineering Industries 371
Oliver POTIER and Mauricio CAMARGO

11.1. Definition of innovation 372

11.2. Field of innovation in the chemical engineering industry 376

11.3. The need for innovation 377

11.4. Methods for innovation in chemical engineering industry 380

11.5. Conclusion 395

11.6. Bibliography 396

Chapter 12. The Place of Intensified Processes in the Plant of the Future 401
Laurent FALK

12.1. Process intensification in the context of sustainable development 401

12.2. Main principles of intensification 404

12.3. Connection between intensification and miniaturization 408

12.4. Applications 414

12.5. New economic models implied by process intensification 416

12.6. Conclusion 429

12.7. Bibliography 430

Chapter 13. Change Management 437
Jean–Pierre DAL PONT

13.1. The company: adapt or die 438

13.2. The company: processes and know–how 438

13.3. Human aspects of change 444

13.4. Basic tools for change management 447

13.5. Changes and improvement of the industrial facility 454

13.6. Re–engineering, the American way 461

13.7. Conclusion 462

13.8. Bibliography 463

Chapter 14. The Plant of the Future 465
Jean–Pierre DAL PONT

14.1. Developed countries companies industrial firms 466

14.2. Typology of means of production 469

14.3. Product and plant design 473

14.4. Management of production and operations (MPO) 477

14.5. The IT revolution IT management 479

14.6. And the individual? 480

14.7. Conclusion 481

14.8. Bibliography 482

List of Authors 485

Index 487