Process Improvement Options

Losses could potentially be reduced by considering, for example, the following options  

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This chapter examines two industrial polymer processes. Thermodynamic analysis is used as a tool to locate, in a matter-of-fact fashion, process inefficiencies. Some sample process improvement options are discussed. 

To achieve further improvements to the washing process, an option was integrated with which it was possible for the user to reduce the water level in the... 

The Dow Fire and Explosion Index (FEI) (12) and the Dow Chemical Exposure Index (CEI) (14) are two commonly used tools that measure inherent safety characteristics. Gowland (25) reports on the use of the FEI and CEI in the development of safety improvements for a urethane plant. Tables 1 and 2 illustrate the application of the FEI and CEI in measuring inherent safety characteristics of process design options. These indices measure the inherent safety characteristics of processes in only two specific areas—fire and explosion hazards and acute chemical inhalation toxicity hazards. Other indices would be required to evaluate other types of hazards. 

Many process improvements were achieved by converting to the LEAM process, as shown in Table 6.2. Three options were tested and compared ... 

Engineering economics is the critical criterion to consider early in design, process improvement, and troublshooting. In this section, we review the role of economics in financial reporting through the balance sheet and the income statement, options for measuring financial attractiveness, operating expense estimation, and capital cost estimation. 

The GTC process improvements enhance the traditional process in each of the four sections through changes in process configurations and operating conditions, alteration of separation schemes, revision of recovery arrangements, increase in the value of byproducts, and reduction in the overall recycles in the plant. The upgrade options may be implemented individually, combined, or through a series of revamps over a period of time. 

LCA is a developing technique to study the environmental effects of an activity, e.g. manufacturing a consumer item, by considering the whole product life cycle. The information gained by this process is used to identify options for reduction of the environmental effects, either by means of process improvements or substitution. Clearly, such a substitution can only be made by conducting two or more parallel studies. This is an area fraught with difficulty. 

During feasibility assessment, improvement options will be evaluated in greater detail with more accurate estimates of costs and benefits based on rigorous process and equipment simulations. The traditional approach for feasibility assessment is to investigate modification options without extensively exploiting interactions between modifications, process conditions, process redesign, heat integration, and equipment... 

The essence of a feasibility project is to investigate the effects of modifications toward existing processes and key equipment and identify critical constraints in existing equipment. Prior to feasibility assessment, the improvement options are usually identified in the idea discovery stage by using the methods discussed in the previous chapters. The million dollar question requiring an answer from the feasibility assessment is Is it feasible to implement the options from the economic, technical, and operational points of view ... 

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