20.500.12556/DKUM-57673 REKONSTRUKCIJSKI NAČRTI IN STRATEŠKE ODLOČITVE V OBSTOJEČIH INDUSTRIJSKIH PROCESIH Retrofit planes and strategic decision-making in existing industrial processes V doktorski disertaciji obravnavamo tematiko s področja rekonstruiranja obstoječih industrijskih procesov. Pri tem podrobneje predstavljamo predlagan koncept za rekonstrukcijo, ki zajema ključne aktivnosti za doseganje izboljšav nerentabilnih kemijskih procesov. Aktivnosti so zajete v predvidenih korakih, kot so spoznavanje procesa, matematično modeliranje, optimiranje, generiranje alternativ in ocena ustreznosti generiranih alternativ. Kompleksna infrastruktura, veliko število nemerljivih podatkov in alternative, ki jih je potrebno v naprej preučiti, so omejitve, ki zahtevajo kompleksen pristop k rekonstrukcijskemu načrtovanju. Obrati v preteklosti niso bili prilagojeni tipičnim rekonstrukcijskim zahtevam, ki bi omogočale večjo energijsko učinkovitost, zadovoljivo produktivnost in rentabilnost. Z ustreznimi modifikacijami se lahko bistveno izboljšajo omenjeni dejavniki in podaljša življenjska doba obstoječih kemijskih procesov. Pri tem imajo ustrezno razviti rekonstrukcijski načrti pomembno vlogo za doseganje konkurenčnosti ob upoštevanju negotovosti, trendov prihodnjih cen in zanimanj po tržnih produktih. Znotraj koncepta sta v prvem delu generiranja alternativ predlagana preprosti in kompleksni sklop tehnoloških izboljšav, ki temeljita na rekonstrukciji obstoječega procesa v smeri novih produktov. Drugi del generiranja alternativ zajema modifikacije v smeri surovinskih, produktnih in tehnoloških izboljšav. Za preprosti in kompleksni sklop izboljšav smo razvili matematične modele na podlagi simulacij kemijskih procesov in matematičnega programiranja za vsako izmed predlaganih alternativ posebej. Sintezni pristop je omogočal hkratno optimiranje procesnih parametrov in koriščenje morebitnih interakcij med procesnimi podsistemi, ki so na videz ločeni. Za surovinske, produktne in z njimi povezane tehnološke izboljšave smo razvili drevesno in mrežno superstrukturo z matematičnimi modeli, ki predstavljajo ustrezno orodje za simultano iskanje najprimernejše procesne alternative glede na optimizacijski kriterij. Razviti koncept za rekonstrukcijsko načrtovanje in prenovo obstoječih kemijskih procesov ter ustvarjene matematične modele smo aplicirali na realnem industrijskem procesu proizvodnje metanola. Rezultati kažejo, da je predlagani rekonstrukcijski koncept na podlagi matematičnih modelov privedel do izboljšav v primeru proizvodne novega produkta dimetil etra z neposredno potjo sinteze iz zemeljskega plina in višjo tržno ceno novega produkta. Prispevek raziskav lahko umestimo na področje rekonstrukcijskega načrtovanja v procesni sistemski tehniki. Načrtovanje zajema veliko količino podatkov na podlagi realnih kemijskih procesov, simulacij, hevrističnih pravil in spoznanj dobljenih tekom generiranja procesnih alternativ. Disertacija ne temelji na strateškem odločanju, temveč na razvoju orodij in tehnik za rekonstruiranje obstoječih procesov in procesnih linij v kemičnih in procesnih industrijah. This doctoral dissertation deals with the topic in the field of reconstruction of the existing industrial processes. It represents in details the proposed concept for the retrofit, which includes key activities for achieving improvements for non-profitable chemical processes. Activities are included within several steps, which are obtaining the knowledge about the process, mathematical modelling, optimization, generation of alternatives and the assessment of the appropriateness of generated alternatives. A complex infrastructure, a large number of non-measurable data and alternatives, which need to be studied in advance, are restrictions that require a complex approach to reconstruction. In the past, chemical plants were not adapted to typical reconstruction requirements that would lead to greater energy efficiency, satisfactory productivity and profitability. By suitable modifications these factors could be significantly improved and the lifetime of chemical processes could be prolonged. Taking into account uncertainty, future price trends and interests for commercial products, suitably developed reconstruction plans play an important role in achieving competitiveness. The first part of generating alternatives proposes simple and complex set of technological improvements. Both sets are based on reconstruction of the existing process so to produce the new products. The second part of generation of alternatives includes modifications in the direction of improvements in raw materials, products and technologies. For simple and complex set of improvements, mathematical models were developed on the basis of simulations of chemical processes and mathematical programming for each proposed alternative separately. Synthesis approach enables simultaneous optimization of process parameters and utilization of potential interactions between those process subsystems that seem to be separated. For improvements in raw materials, products and related technological improvements, a superstructure-based model was developed as a tool for simultaneously determining the most suitable alternative with regard to optimization criterion. The developed concept for reconstruction planning and retrofit of existing chemical processes, and developed mathematical model were applied to an industrial process of methanol production. The results show that the proposed concept of retrofit on the basis of mathematical models led to improvements in the case of production of a new product that has higher price in the market. The contribution of this research may be placed on the field of reconstruction planning in process system engineering. Planning includes a large amount of data on the basis of realistic chemical processes, simulations, heuristic rules and knowledge during generation of alternatives. This dissertation is not based on strategic decision-making, but on the development of tools and techniques for retrofitting of industrial processes. rekonstrukcija sintezni pristop matematično programiranje obstoječ industrijski proces generiranje procesnih alternativ retrofit synthesis approach mathematical programming generated alternatives industrial process generation of process alternatives true true false [J. Hosnar] Slovenski jezik Angleški jezik Doktorsko delo/naloga 2016-03-08 14:18:36 2016-07-11 13:55:25 2022-06-15 03:08:20 2019-07-11 10:14:30 2016 0 Maribor 0 0000-00-00 NiDoloceno NiDoloceno NiDoloceno 0000-00-00 0000-00-00 0000-00-00 519.8:[606:62](043.3) 19670806 URN:SI:UM:DK:URGH6WM7 DOK_Hosnar_Jernej_2016.pdf DOK_Hosnar_Jernej_2016.pdf 1 4792938146971286048E729FCBAD5540 f86822f0ed40b7e96a2326d2e20bc5c189f1efd7b568c45709855fd494c3b246 ddf511c9-7c0c-11eb-bb7a-00155d0001ca https://dk.um.si/Dokument.php?lang=slv&id=96334 Fakulteta za kemijo in kemijsko tehnologijo 0 0 0