How can you maintain an efficient chemical process?

Set clear objectives for realistic targets. As a chemical engineer, follow thermodynamic laws for energy efficiency. Care for cooling water chemistry to prevent exchanger fouling. Optimize furnace and fuel consumption by checking radiant and convection efficiency. Examine pumps/compressors for unnecessary recycling. Address faulty steam traps, damaged insulation, and leaks in vent valves to avoid losses. Inspect valves, separators, reactors for abnormal pressure drops to minimize energy loss.

Two paradigms: 1. Conduct of Operations 2. Duty of Care For efficient operations, set and monitor KPIs around: - operate within the operating envelope - Keep the IoW (Integrity Operating Window) in check - Maintain checks on fouling of heat exhangers, piping - Identity and reduce fluid hammering - Maintain steam traps - Inspect, test and maintain equipment, e.g: relief valves, control valves, BPCS, pumps, compressors etc. - Flare gas recovery - LDAR progrm (Leak Detection And Repair) - Planning and scheduling all turnarounds - spare management. Thanks

Uma questão que precisa ser levada em consideração numa melhoria de performance é o projeto. Toda instalação industrial é concebida tendo como pilar de sustentação seu projeto conceitual, que inclui uma definição de escopo e o projeto de engenharia, que inclui o básico e detalhamento. Qualquer otimização passa por estes estudos, até a definição da viabilidade de sair destes parâmetros ou não. Para qualquer avaliação é necessário ter uma visão holística da operação, para a segurança do processo e para obter os ganhos buscados. Tudo passa por Engenharia e Profissionais especializados e com elevado conhecimento.

A primeira ação que deve ser feita é medir, através de um kpi ou mais, os parâmetros que se quer melhorar. Isso vai ajudar a avaliar os resultados durante o acompanhamento das melhorias, lá na etapa final "Plano de ação"

To establish an efficient chemical process: 1. 𝗗𝗲𝗳𝗶𝗻𝗲 𝗘𝗳𝗳𝗶𝗰𝗶𝗲𝗻𝗰𝘆 𝗚𝗼𝗮𝗹𝘀: Determine specific aims, like maximizing yield, reducing waste, or meeting quality standards. 2. 𝗦𝗲𝘁 𝗞𝗣𝗜𝘀: Identify key metrics such as conversion rate, selectivity, or profitability to track efficiency. 3. 𝗥𝗲𝗮𝗹𝗶𝘀𝘁𝗶𝗰 𝗜𝗺𝗽𝗿𝗼𝘃𝗲𝗺𝗲𝗻𝘁 𝗧𝗮𝗿𝗴𝗲𝘁𝘀: Set achievable targets based on your goals and KPIs, considering current process capabilities. 4. 𝗥𝗲𝗴𝘂𝗹𝗮𝗿 𝗥𝗲𝘃𝗶𝗲𝘄: Continuously reassess these targets to adapt to process changes or external factors. Clear goals and measurable indicators are essential for systematically improving chemical process efficiency.

To optimise chemical process efficiency: 1. 𝗖𝗼𝗻𝘀𝗶𝘀𝘁𝗲𝗻𝘁 𝗗𝗮𝘁𝗮 𝗖𝗼𝗹𝗹𝗲𝗰𝘁𝗶𝗼𝗻: Regularly gather key process data, including temperature, pressure, and yields. 2. 𝗣𝗿𝗼𝗰𝗲𝘀𝘀 𝗗𝘆𝗻𝗮𝗺𝗶𝗰𝘀 𝗔𝗻𝗮𝗹𝘆𝘀𝗶𝘀: Use this data to understand the behavior and efficiency of the process, identifying patterns and inefficiencies. 3. 𝗗𝗲𝘁𝗲𝗰𝘁 𝗜𝘀𝘀𝘂𝗲𝘀: Analyze data to spot inefficiencies or problems. 4. 𝗔𝗻𝗮𝗹𝘆𝘁𝗶𝗰𝗮𝗹 𝗧𝗼𝗼𝗹𝘀: Apply mass and energy balances, statistical methods, and process modeling. Consider AI and machine learning for deeper insights. 5. 𝗜𝗻𝗳𝗼𝗿𝗺 𝗜𝗺𝗽𝗿𝗼𝘃𝗲𝗺𝗲𝗻𝘁𝘀: Use insights from data analysis to hypothesize and implement process enhancements.

Analyzing & Evaluation of Process dynamics can help regulate the key parameters for optimized productivity at little push. Continuous monitoring can be done while drawing plots against key parameters, Analyzing results, Visualizing the change of a certain variable & connect that analyzed data to Hysys/UNISIM/DWSIM simulator where you can simulate an entire scenario with certain variations in variables that will give you a real time exposure & you can identify the worth of changing a single variable to desired productive quality.

Um exemplo que pode ser colocado em uso é a falha de qualidade de um produto, onde o indicador (kpi) escolhido mostra as tendências frente a outras mudanças no processo. Além disso, é possível avaliar o comportamento do processo diante da sua variabilidade. Existem inúmeras ferramentas estatísticas para isso.

The following strategies need to be implemented in order to guarantee that the chemical process will run reliably and efficiently: Firstly, make adjustments to the machinery, the space, or the environmental factors in order to increase productivity. Secondly, make use of controllers and sensors to ensure consistent process control. Also, inspect and repair equipment on a regular basis to keep it running efficiently. Lastly, evaluate and enhance the reliability of the system to avoid malfunctions.

A otimização é a última etapa de um processo. Primeiro é necessário conhecê-lo para então propor melhorias. As melhorias podem ser o etapas do ciclo de PDCA simples, que evolui em espiral (D = fazer /A = ação).

To optimise a chemical process: 1. 𝗗𝗲𝘀𝗶𝗴𝗻 𝗮𝗻𝗱 𝗢𝗽𝘁𝗶𝗺𝗶𝘇𝗮𝘁𝗶𝗼𝗻: Modify equipment, layout, or conditions for better efficiency. 2. 𝗜𝗺𝗽𝗹𝗲𝗺𝗲𝗻𝘁 𝗔𝘂𝘁𝗼𝗺𝗮𝘁𝗶𝗼𝗻: Use sensors and controllers for consistent process control. 3. 𝗠𝗮𝗶𝗻𝘁𝗲𝗻𝗮𝗻𝗰𝗲 𝗣𝗿𝗮𝗰𝘁𝗶𝗰𝗲𝘀: Regularly inspect and repair equipment to maintain efficiency. 4. 𝗣𝗿𝗲𝗱𝗶𝗰𝘁𝗶𝘃𝗲 𝗠𝗮𝗶𝗻𝘁𝗲𝗻𝗮𝗻𝗰𝗲: Schedule maintenance based on equipment performance. 5. 𝗥𝗲𝗹𝗶𝗮𝗯𝗶𝗹𝗶𝘁𝘆 𝗘𝗻𝗴𝗶𝗻𝗲𝗲𝗿𝗶𝗻𝗴: Analyse and improve system dependability to prevent failures. These strategies ensure the chemical process operates at peak efficiency and reliability.

Essa é a etapa "Check" do PDCA. O feedback retroalimenta o processo, mostrando a eficácia das ações tomadas. Portanto, há uma evolução, pois sempre esse ponto é um update do processo anterior

To maintain an efficient chemical process: 1. 𝗠𝗲𝗮𝘀𝘂𝗿𝗲 𝗜𝗺𝗽𝗿𝗼𝘃𝗲𝗺𝗲𝗻𝘁𝘀: Compare actual results with expected outcomes using KPIs and data tools, assessing the impact of implemented strategies. 2. 𝗦𝗵𝗮𝗿𝗲 𝗙𝗲𝗲𝗱𝗯𝗮𝗰𝗸: Communicate findings with design, operation, and maintenance teams for continuous process improvement. 3. 𝗜𝗻𝗳𝗼𝗿𝗺 𝗦𝘁𝗮𝗸𝗲𝗵𝗼𝗹𝗱𝗲𝗿𝘀: Keep stakeholders and customers updated on process enhancements and results. 4. 𝗜𝗱𝗲𝗻𝘁𝗶𝗳𝘆 𝗜𝗺𝗽𝗿𝗼𝘃𝗲𝗺𝗲𝗻𝘁 𝗔𝗿𝗲𝗮𝘀: Use feedback to pinpoint further optimization opportunities, ensuring ongoing efficiency enhancements. Regular evaluation and open communication are key to sustaining and improving process efficiency.

Implement well structured knowledge and skills development systems and processes supported by structured development quality assurance processes to ensure that staff are knowledgeable and have a clear vision of their roles and responsibilities.

Studying the trends in operating parameters Timely calibration of instruments Root cause analysis when things go wrong and applying the lessons to improve the process safety.

Keep plant equipment in good condition: Regular equipment maintenance is essential to ensure that production schedules are met smoothly. Use advanced technologies: Advanced technology can help improve the efficiency of the chemical process. For example, the use of smart sensors and advanced control systems can help ensure that the process is running optimally. Train staff: Staff must be trained to ensure the process is executed efficiently. This may include training in the use of advanced technologies, problem identification and resolution, and process optimization, among others.