The document describes optimization of the grade change process on a paper machine to minimize downtime through implementation of critical path method (CPM). CPM was used to analyze the sequence of activities during grade changes and identify opportunities to reduce dependencies between activities. This allowed certain activities to be performed in parallel, reducing the total time of grade changes by 15-20 minutes. Further improvements like adding additional drain/fill lines and automating some valves are suggested to reduce time further. For critical quality changes, modifications to the approach flow system were made to eliminate the need to clean some parts of the system simultaneously.
This presentation was given at the Philadelphia AiChE continuing education meeting of 23 April 2018. HiGee (high gravity) technology for gas-liquid mass transfer is discussed, as one means of process intensification. The history of its development is treated, along explanation of the technology and the evolution of the equipment designs. Literature examples of applications are listed, with some data for a few of these, comparing to conventional distillation and mass-transfer technologies. An evaluation of the technology is given. While fouling services may be a challenge, this technology would have a place in certain applications in US industry.
The document provides guidance on designing ion exchange plants, covering key parameters to consider such as feed water analysis, production flow rate, cycle length, treated water quality requirements, and regeneration technology. It recommends reverse flow regeneration and packed bed columns for efficient design and high quality treated water. An example calculation is provided to estimate resin volumes needed for a simple demineralization system based on the water analysis and design parameters.
1) The document outlines the step-by-step procedure for unloading the catalyst from a synthesis converter, including cooling down the catalyst bed, purging the synthesis loop with inert gas, dismantling connected pipelines and valves, and preparing for catalyst extraction.
2) The first basket catalyst is extracted using a vacuum system with inert gas bleed and safety precautions like breathing apparatus and safety ropes for workers inside the converter.
3) Once the first basket catalyst is extracted, the second basket catalyst is extracted following similar safety procedures, and then the second basket is removed along with the low pressure shell.
The document summarizes laboratory experiments on Surfactant Alternate Gas (SAG) injection as an enhanced oil recovery technique for the Limbodara oil field in India. Core flood experiments showed that single cycle SAG injection achieved an incremental oil recovery of 27.79% over waterflooding, while two cycle SAG injection achieved 29.01% incremental recovery. The SAG process improved sweep efficiency through factors like mobility control and contact of unswept zones. The study demonstrated the feasibility of additional oil recovery through immiscible SAG injection in parts of the field experiencing early water breakthrough.
This document summarizes the annual catalyst unloading and reloading process for the primary reformer at a chemical plant. It describes removing the spent catalyst from 224 tubes using vacuum pumps over 48 hours. Samples were taken and tubes were cleaned. New catalyst was then loaded in two layers - a bottom layer of nickel catalyst in 5 buckets per tube and a top layer of nickel-potassium catalyst in 7 buckets per tube. Dip heights and pressure drops were measured to ensure proper loading. The process was completed over 11 days during the annual turnaround.
The advantages of ASCOM separators and internals include:
- Minimum size while maximizing separation efficiency of liquids from gas and oil from water
- Less sensitivity to wave motion and excellent turndown characteristics
- Low pressure drop and ability to handle clean and fouling services
- Robust, maintenance-free design that can be installed through manways without welding
about 70 % of the existing reservoirs are impossible to reach with conventional drilling . MPD or managed pressure drilling is the best solution for HPHT and very deep reservoirs .
The document discusses the design optimization of an adsorber column header used in a helium purifier. Helium purification is needed to remove impurities introduced during liquefaction and other processes. Computational fluid dynamics (CFD) analysis was performed using ANSYS Fluent to analyze flow characteristics in header designs with inlet angles ranging from 90 to 20 degrees. Results showed flow distribution became more uniform as the inlet angle decreased. A 30 degree inlet angle was selected as it provided good flow characteristics while also considering manufacturability. Further optimizations to the header design could improve flow uniformity, such as adding guiding plates or modifying corner geometries.
This presentation was given at the Philadelphia AiChE continuing education meeting of 23 April 2018. HiGee (high gravity) technology for gas-liquid mass transfer is discussed, as one means of process intensification. The history of its development is treated, along explanation of the technology and the evolution of the equipment designs. Literature examples of applications are listed, with some data for a few of these, comparing to conventional distillation and mass-transfer technologies. An evaluation of the technology is given. While fouling services may be a challenge, this technology would have a place in certain applications in US industry.
The document provides guidance on designing ion exchange plants, covering key parameters to consider such as feed water analysis, production flow rate, cycle length, treated water quality requirements, and regeneration technology. It recommends reverse flow regeneration and packed bed columns for efficient design and high quality treated water. An example calculation is provided to estimate resin volumes needed for a simple demineralization system based on the water analysis and design parameters.
1) The document outlines the step-by-step procedure for unloading the catalyst from a synthesis converter, including cooling down the catalyst bed, purging the synthesis loop with inert gas, dismantling connected pipelines and valves, and preparing for catalyst extraction.
2) The first basket catalyst is extracted using a vacuum system with inert gas bleed and safety precautions like breathing apparatus and safety ropes for workers inside the converter.
3) Once the first basket catalyst is extracted, the second basket catalyst is extracted following similar safety procedures, and then the second basket is removed along with the low pressure shell.
The document summarizes laboratory experiments on Surfactant Alternate Gas (SAG) injection as an enhanced oil recovery technique for the Limbodara oil field in India. Core flood experiments showed that single cycle SAG injection achieved an incremental oil recovery of 27.79% over waterflooding, while two cycle SAG injection achieved 29.01% incremental recovery. The SAG process improved sweep efficiency through factors like mobility control and contact of unswept zones. The study demonstrated the feasibility of additional oil recovery through immiscible SAG injection in parts of the field experiencing early water breakthrough.
This document summarizes the annual catalyst unloading and reloading process for the primary reformer at a chemical plant. It describes removing the spent catalyst from 224 tubes using vacuum pumps over 48 hours. Samples were taken and tubes were cleaned. New catalyst was then loaded in two layers - a bottom layer of nickel catalyst in 5 buckets per tube and a top layer of nickel-potassium catalyst in 7 buckets per tube. Dip heights and pressure drops were measured to ensure proper loading. The process was completed over 11 days during the annual turnaround.
The advantages of ASCOM separators and internals include:
- Minimum size while maximizing separation efficiency of liquids from gas and oil from water
- Less sensitivity to wave motion and excellent turndown characteristics
- Low pressure drop and ability to handle clean and fouling services
- Robust, maintenance-free design that can be installed through manways without welding
about 70 % of the existing reservoirs are impossible to reach with conventional drilling . MPD or managed pressure drilling is the best solution for HPHT and very deep reservoirs .
The document discusses the design optimization of an adsorber column header used in a helium purifier. Helium purification is needed to remove impurities introduced during liquefaction and other processes. Computational fluid dynamics (CFD) analysis was performed using ANSYS Fluent to analyze flow characteristics in header designs with inlet angles ranging from 90 to 20 degrees. Results showed flow distribution became more uniform as the inlet angle decreased. A 30 degree inlet angle was selected as it provided good flow characteristics while also considering manufacturability. Further optimizations to the header design could improve flow uniformity, such as adding guiding plates or modifying corner geometries.
Redesigned Filter Capsule Improves Final Filtration Assembly Design and Opera...MilliporeSigma
This application note describes testing performed to assess volume loss in SURF assemblies and shows how both assembly design and filtration operations can be adapted to minimize volume and product loss in the system.
The document discusses advanced design concepts for reverse osmosis systems, including selecting membrane elements based on feed water quality and permeate requirements, balancing flux across multi-stage arrays, and using internally staged designs or multi-element hybrid arrays to improve performance and permeate quality while reducing energy usage and total cost of water. The document provides guidelines on variables to consider for RO system design based on application and goals of minimizing capital or operational costs.
This document provides an introduction to chemical dosing systems. It begins by explaining what chemical dosing is and why it is used to condition boiler feedwater and prevent corrosion and scale formation. It then describes the basics of dosing pumps and the key components of dosing systems, which typically include storage tanks, piping, valves, and instrumentation. The document outlines common applications of dosing systems in various industries and provides details on dosing pump types, characteristics, and flow control mechanisms.
Crude oil washing is a process where crude oil cargo is used to rinse residue from oil tanker storage tanks after cargo discharge. Using crude oil is more effective at removing residue than water washing alone. It reduces pollution by minimizing the discharge of oil-contaminated water and increases the amount of cargo discharged. The development of crude oil washing in the late 1970s improved on previous water-based cleaning methods by relying on crude oil cargo to dissolve residue, resulting in less pollution and increased cargo recovery.
This document discusses tank cleaning and degassing services provided by Clean World Innovations. It offers turnkey tank cleaning operations using a patented warm water method. This method involves removing crude from the tank, adding a water-chemical solution and diluent, and circulating the mixture to lift sludge off the tank floor. Case studies demonstrate sludge removal and recovery of over 90% of oil. The company also provides tank degassing using chemical solutions to rapidly remove hydrocarbon vapors from tanks, allowing for safe maintenance work.
The document discusses determining the optimal dosage of superplasticizer admixtures using the Marsh cone test. It provides background on admixtures and describes a case study where different dosages of a superplasticizer were tested on two cement types to evaluate the optimum dosage. Tables show Marsh cone test results for each cement type at dosages from 0.1-0.5%. Graphs identify the saturation zone and optimum dosage as 0.425-0.45% for OPC cement and 0.3-0.35% for PPC cement. The conclusion is that the optimal superplasticizer dosage can differ between cement types even at the same water-cement ratio.
Hamed Establishment GTC (HEST) is a subsidiary of Bin Butti Group Of Companies established in 1990 in Abu Dhabi serving major oil companies in the region. HEST provides tank cleaning, sludge removal, treatment and disposal services using specialized equipment and technology. It has an annual turnover of 200 million USD and assets worth 600 million USD with facilities in Fujairah, Mussafah and Ruwais. HEST has the technical expertise and equipment to safely clean and remove sludge from tanks using remote controlled systems. It also offers tank repair services including bottom plate replacement, roof repairs and painting.
GTC's High Performance Tray Tower SolutionsGTC Technology
This document provides an overview of GTC Technology, a global licensor of process technologies and mass transfer solutions. It discusses GTC's proprietary and conventional tray solutions for distillation columns, including their high performance GT-OPTIM trays. The GT-OPTIM trays are designed to achieve plug flow for increased efficiency and capacity compared to conventional trays. The document also outlines GTC's engineering services for distillation column revamps and customized tray designs.
Drew Hanover completed a summer internship at GM in 2015 working on the Wipers & Washers Group. He led two DFSS projects, one analyzing the optimal pump height to minimize debris ingestion, and another looking at issues with dual outlet pumps expelling excess fluid. For the pump height project, he designed experiments testing various heights both continuously and modulated to determine static versus dynamic conditions affect debris ingestion. For the dual outlet pump project, he is setting up experiments varying factors like temperature, hose length, and manufacturer to identify causes of excess fluid expulsion and potential solutions. The internship improved his communication and relationship building skills while contributing meaningful work to GM.
who student are interested for slide regarding the biotechnology subject please send mail at shubhammaurya97938@gmail.com
it will help as notes.
this slide will help who love the environment,as well as will help to get the basic knowledge regarding STP.
This document is a final project report submitted by a team of 4 students - Alan Tam, Yuanyuan Liu, Joseph Guarnes, and Thanh-Phuong Nguyen. The report details their project to optimize the removal of ammonium hydroxide from an ethanol solution waste stream using either a distillation column or a bubble bed/carbon bed system. It provides background on the Stober silica process that creates the waste stream, evaluates past research methods, outlines their design specifications for the two proposed methods, analyzes safety considerations, and estimates sizing and costs.
This document is a final project report submitted by a team of 4 students - Alan Tam, Yuanyuan Liu, Joseph Guarnes, and Thanh-Phuong Nguyen. The report details their project to optimize the removal of ammonium hydroxide from an ethanol waste stream using either a distillation column or a bubble bed/carbon bed system. It provides background on the Stober silica process that creates the waste stream, evaluates past research methods, outlines their design specifications for the two proposed methods, analyzes safety considerations, and estimates sizing and costs.
This document discusses design guidelines for propylene splitters. It begins with an introduction to factors that affect tower efficiency like pressure, geometry, flow rates, and compositions. It then discusses typical field efficiencies for different tower types based on published data. The document reviews how pressure, viscosity, and volatility affect efficiency based on O'Connell correlations. It also discusses the effects of pressure on tray and packing efficiencies. The document concludes with discussions on best practices for tray and splitter design and considerations for high versus low pressure splitters.
This document discusses increasing profits through in-tank sludge cleaning and recovery. The process involves less downtime and equipment than traditional methods. Recovered sludge is an income stream that increases storage capacity and cleaner pipelines while producing less waste. The process uses infrared imaging to determine sludge accumulation and installs jets and pumps to create a vortex and suspend the sludge for safe transport to refineries. It reduces liability, adheres to monitoring, and recovers costs while cleaning tanks and pipelines effectively with minimal environmental impact.
An orientation on changes to Caltrans asphalt pavement specifications to incorporate elements of the national "Superpave" standard. Presented by Joe Peterson, chief, Office of Roadway Materials Testing for Caltrans at the Dec. 3, 2014 CalAPA L.A. and High Desert Technical Committee meeting in Fontana.
ARKOIL Technologies_oil tank cleaning_finalAmir Dzugatti
The document describes ARKOIL Technologies' non-man entry system for cleaning storage tanks and recovering hydrocarbons. It was developed for cleaning all types and sizes of storage tanks without the need for personnel to enter the tanks. The system uses steam to liquefy sludge and separate it into oil, water, and solid fractions. More than 1,000 tanks have been cleaned using this system with almost 100% hydrocarbon recovery and without damaging tank coatings or requiring chemicals.
The document provides information about Degremont China and its portfolio of water treatment equipment. It introduces several types of equipment including the AQUADAF PS for rapid flotation clarification, COMPAKBLUE for tertiary filtration using immersed disk filters, DCI for pre-treatment of oily effluent using a new generation of circular separators, and others. It also provides brief descriptions of the applications and benefits of these equipment.
This document discusses cement classification, slurry design, and additives used in oil well cementing. It describes the four main components of Portland cement and their functions. It outlines the API classification system for oil well cements based on depth and characteristics. Key factors influencing cement slurry design are identified as well depth, temperature, and pressure. Important slurry parameters like density, thickening time, rheology, and fluid loss are discussed. Common additives used as accelerators, retarders, dispersants, and for fluid loss control are identified.
This document discusses manpower training in small paper mills. It notes that small mills often lack formal training systems compared to larger mills. Lower level workers in small mills tend to be less skilled than higher levels. The document proposes several actions for small mill training, including regular knowledge tests, weekly quizzes, and developing multimedia training tools. It provides examples of gains from training, such as reduced paper weight variations and increased condensate return. Overall the document advocates for customized training approaches for small mills to improve worker skills and productivity.
Redesigned Filter Capsule Improves Final Filtration Assembly Design and Opera...MilliporeSigma
This application note describes testing performed to assess volume loss in SURF assemblies and shows how both assembly design and filtration operations can be adapted to minimize volume and product loss in the system.
The document discusses advanced design concepts for reverse osmosis systems, including selecting membrane elements based on feed water quality and permeate requirements, balancing flux across multi-stage arrays, and using internally staged designs or multi-element hybrid arrays to improve performance and permeate quality while reducing energy usage and total cost of water. The document provides guidelines on variables to consider for RO system design based on application and goals of minimizing capital or operational costs.
This document provides an introduction to chemical dosing systems. It begins by explaining what chemical dosing is and why it is used to condition boiler feedwater and prevent corrosion and scale formation. It then describes the basics of dosing pumps and the key components of dosing systems, which typically include storage tanks, piping, valves, and instrumentation. The document outlines common applications of dosing systems in various industries and provides details on dosing pump types, characteristics, and flow control mechanisms.
Crude oil washing is a process where crude oil cargo is used to rinse residue from oil tanker storage tanks after cargo discharge. Using crude oil is more effective at removing residue than water washing alone. It reduces pollution by minimizing the discharge of oil-contaminated water and increases the amount of cargo discharged. The development of crude oil washing in the late 1970s improved on previous water-based cleaning methods by relying on crude oil cargo to dissolve residue, resulting in less pollution and increased cargo recovery.
This document discusses tank cleaning and degassing services provided by Clean World Innovations. It offers turnkey tank cleaning operations using a patented warm water method. This method involves removing crude from the tank, adding a water-chemical solution and diluent, and circulating the mixture to lift sludge off the tank floor. Case studies demonstrate sludge removal and recovery of over 90% of oil. The company also provides tank degassing using chemical solutions to rapidly remove hydrocarbon vapors from tanks, allowing for safe maintenance work.
The document discusses determining the optimal dosage of superplasticizer admixtures using the Marsh cone test. It provides background on admixtures and describes a case study where different dosages of a superplasticizer were tested on two cement types to evaluate the optimum dosage. Tables show Marsh cone test results for each cement type at dosages from 0.1-0.5%. Graphs identify the saturation zone and optimum dosage as 0.425-0.45% for OPC cement and 0.3-0.35% for PPC cement. The conclusion is that the optimal superplasticizer dosage can differ between cement types even at the same water-cement ratio.
Hamed Establishment GTC (HEST) is a subsidiary of Bin Butti Group Of Companies established in 1990 in Abu Dhabi serving major oil companies in the region. HEST provides tank cleaning, sludge removal, treatment and disposal services using specialized equipment and technology. It has an annual turnover of 200 million USD and assets worth 600 million USD with facilities in Fujairah, Mussafah and Ruwais. HEST has the technical expertise and equipment to safely clean and remove sludge from tanks using remote controlled systems. It also offers tank repair services including bottom plate replacement, roof repairs and painting.
GTC's High Performance Tray Tower SolutionsGTC Technology
This document provides an overview of GTC Technology, a global licensor of process technologies and mass transfer solutions. It discusses GTC's proprietary and conventional tray solutions for distillation columns, including their high performance GT-OPTIM trays. The GT-OPTIM trays are designed to achieve plug flow for increased efficiency and capacity compared to conventional trays. The document also outlines GTC's engineering services for distillation column revamps and customized tray designs.
Drew Hanover completed a summer internship at GM in 2015 working on the Wipers & Washers Group. He led two DFSS projects, one analyzing the optimal pump height to minimize debris ingestion, and another looking at issues with dual outlet pumps expelling excess fluid. For the pump height project, he designed experiments testing various heights both continuously and modulated to determine static versus dynamic conditions affect debris ingestion. For the dual outlet pump project, he is setting up experiments varying factors like temperature, hose length, and manufacturer to identify causes of excess fluid expulsion and potential solutions. The internship improved his communication and relationship building skills while contributing meaningful work to GM.
who student are interested for slide regarding the biotechnology subject please send mail at shubhammaurya97938@gmail.com
it will help as notes.
this slide will help who love the environment,as well as will help to get the basic knowledge regarding STP.
This document is a final project report submitted by a team of 4 students - Alan Tam, Yuanyuan Liu, Joseph Guarnes, and Thanh-Phuong Nguyen. The report details their project to optimize the removal of ammonium hydroxide from an ethanol solution waste stream using either a distillation column or a bubble bed/carbon bed system. It provides background on the Stober silica process that creates the waste stream, evaluates past research methods, outlines their design specifications for the two proposed methods, analyzes safety considerations, and estimates sizing and costs.
This document is a final project report submitted by a team of 4 students - Alan Tam, Yuanyuan Liu, Joseph Guarnes, and Thanh-Phuong Nguyen. The report details their project to optimize the removal of ammonium hydroxide from an ethanol waste stream using either a distillation column or a bubble bed/carbon bed system. It provides background on the Stober silica process that creates the waste stream, evaluates past research methods, outlines their design specifications for the two proposed methods, analyzes safety considerations, and estimates sizing and costs.
This document discusses design guidelines for propylene splitters. It begins with an introduction to factors that affect tower efficiency like pressure, geometry, flow rates, and compositions. It then discusses typical field efficiencies for different tower types based on published data. The document reviews how pressure, viscosity, and volatility affect efficiency based on O'Connell correlations. It also discusses the effects of pressure on tray and packing efficiencies. The document concludes with discussions on best practices for tray and splitter design and considerations for high versus low pressure splitters.
This document discusses increasing profits through in-tank sludge cleaning and recovery. The process involves less downtime and equipment than traditional methods. Recovered sludge is an income stream that increases storage capacity and cleaner pipelines while producing less waste. The process uses infrared imaging to determine sludge accumulation and installs jets and pumps to create a vortex and suspend the sludge for safe transport to refineries. It reduces liability, adheres to monitoring, and recovers costs while cleaning tanks and pipelines effectively with minimal environmental impact.
An orientation on changes to Caltrans asphalt pavement specifications to incorporate elements of the national "Superpave" standard. Presented by Joe Peterson, chief, Office of Roadway Materials Testing for Caltrans at the Dec. 3, 2014 CalAPA L.A. and High Desert Technical Committee meeting in Fontana.
ARKOIL Technologies_oil tank cleaning_finalAmir Dzugatti
The document describes ARKOIL Technologies' non-man entry system for cleaning storage tanks and recovering hydrocarbons. It was developed for cleaning all types and sizes of storage tanks without the need for personnel to enter the tanks. The system uses steam to liquefy sludge and separate it into oil, water, and solid fractions. More than 1,000 tanks have been cleaned using this system with almost 100% hydrocarbon recovery and without damaging tank coatings or requiring chemicals.
The document provides information about Degremont China and its portfolio of water treatment equipment. It introduces several types of equipment including the AQUADAF PS for rapid flotation clarification, COMPAKBLUE for tertiary filtration using immersed disk filters, DCI for pre-treatment of oily effluent using a new generation of circular separators, and others. It also provides brief descriptions of the applications and benefits of these equipment.
This document discusses cement classification, slurry design, and additives used in oil well cementing. It describes the four main components of Portland cement and their functions. It outlines the API classification system for oil well cements based on depth and characteristics. Key factors influencing cement slurry design are identified as well depth, temperature, and pressure. Important slurry parameters like density, thickening time, rheology, and fluid loss are discussed. Common additives used as accelerators, retarders, dispersants, and for fluid loss control are identified.
This document discusses manpower training in small paper mills. It notes that small mills often lack formal training systems compared to larger mills. Lower level workers in small mills tend to be less skilled than higher levels. The document proposes several actions for small mill training, including regular knowledge tests, weekly quizzes, and developing multimedia training tools. It provides examples of gains from training, such as reduced paper weight variations and increased condensate return. Overall the document advocates for customized training approaches for small mills to improve worker skills and productivity.
This document summarizes improvements made to a paper machine's MG steam and condensate system. It was found that directing condensate directly from the MG to the boiler house via appropriately sized piping eliminated issues, improved efficiency, and reduced costs. Additional benefits were realized by installing a heat exchanger to further increase condensate return and recovery of flash steam. Overall, the changes reduced downtime, steam consumption, and improved condensate return and hot water availability for other processes.
Benchmarking In Papermaking Processes By D K Singhaldeveshksinghal
Benchmarking is a technique used to compare process performance metrics between organizations producing similar products. This document discusses using benchmarking to analyze key performance indicators like water, power, and material consumption. It provides examples of single parameter benchmarks comparing values like specific water consumption between different paper mills. The document also discusses limitations of some common benchmarks and proposes better benchmarks like virgin fiber consumption that provide a more accurate picture of environmental performance between countries. Overall, the document advocates for benchmarking as a tool to identify improvement opportunities and monitor process performance over time.
This document welcomes parents to Mrs. Dairo's class and outlines what skills their children will learn, including independent living skills like using the bathroom and cleaning up independently, as well as early reading skills such as holding books properly and identifying sight words, and writing skills starting with scribbling and tracing before learning to write their own name.
This document summarizes improvements made to a paper machine's MG steam and condensate system. It was found that directing condensate directly from the MG to the boiler house via appropriately sized piping eliminated issues, improved efficiency, and reduced costs. Additional benefits were realized by installing a heat exchanger to recover latent heat from the condensate before it reached the boiler. This increased condensate return rates and reduced blowdown requirements. The low-cost modifications provided significant operational and financial benefits with short payback periods.
This document is the title page and copyright information for the book "Applied Multivariate Techniques" by Subhash Sharma. It lists the author as Subhash Sharma from the University of South Carolina. The book is published by John Wiley & Sons, Inc. in New York, Chichester, Brisbane, Toronto and Singapore. The document provides basic publication details for the book but no other context or content.
Levi9 is an IT services company founded in 2005 that employs 300 IT professionals across Ukraine, Serbia, and Romania. It offers application development and maintenance services in Java and Microsoft technologies using agile, waterfall, and team as a service models. Levi9 has a variety of independent software vendor and end client customers in the Netherlands, including TomTom, Exact, Xerox, and various government ministries. The company emphasizes its highly skilled yet affordable workforce from Central and Eastern Europe, Western practices, customer-focused structure, and ability to serve both small and large customers.
Optimization Of Grade Change By D K Singhaldeveshksinghal
This document describes how the author optimized the grade change process on a paper machine to minimize downtime through implementation of the critical path method. By analyzing each step in the process and identifying dependencies between steps, the author was able to reduce the downtime from 1.5-2 hours to under 1 hour. Further improvements like adding additional drainage lines reduced time further. For critical quality changes, modifications like using separate decker and tanks helped reduce changeover time significantly. Automating some steps through PLC control could reduce time by another 5-9 minutes. Overall, implementing CPM and related improvements reduced downtime by over 50-60% for grade changes.
This document proposes a low-cost system for measuring steam flow in industrial processes. The system works by measuring the pressure drop across a steam pipeline, which is proportional to the square of the steam flow rate. A tank with a partition is installed in the pipeline, and the pressure difference is indicated by the water level in a gauge glass. By taking initial measurements and developing a plant-specific correlation, the steam flow can be estimated based on the pressure drop and used to optimize steam consumption. The proposed system provides a low-cost alternative for steam flow monitoring where more expensive meters cannot be afforded.
The document discusses the benefits of using treated effluent from waste paper based paper mills for irrigation purposes. It notes that contrary to popular belief, the effluent from these mills contains non-hazardous chemicals and its use has been shown to increase crop yields by up to 20% in some cases. The effluent is rich in nutrients and its use can improve soil quality while reducing farmers' costs and electricity usage. Several published studies on the effects of treated paper mill effluent irrigation are summarized, with most finding benefits to crop growth and yield. Results from a specific mill also saw sugarcane heights and production increase by around 20% when using the treated effluent for irrigation.
The assembly discusses the importance of being open-minded as a sixth form student and beyond. It encourages students to use their free time to expand their knowledge and understanding through reading books, newspapers, magazines, and exploring different perspectives online or through other media. Being open-minded means understanding other cultures and views without being uncritical, and seeking a variety of viewpoints to continue growing intellectually. A closed mind can lead to fear and hate while an open mind is a sign of security and understanding of other people.
The document discusses design considerations for mild steel MG cylinders used in papermaking. It covers topics like material selection, plate testing, fabrication process including welding and stress relieving, and mechanical design factors like shell thickness and tie rods. Stress relieving is important to reduce residual stresses from fabrication and welding. An energy audit of the stress relieving process can ensure it is done correctly.
This document is a resume for Divya Jain. It summarizes her work experience, education, skills, and qualifications. Currently, she works as a part-time lecturer at Vogue Institute of Fashion Technology, teaching subjects like accounts and statistics. Previously, she owned a coaching institute called Learning Curves and worked as an operations executive at Axis Bank. She holds an MBA in International Business from Guru Jambheshwar University and has experience in teaching, banking operations, and research. Her technical skills include teaching various business subjects and statistics, and her computer skills include Microsoft Office, SPSS, and banking software.
The document discusses the benefits of standby time in adsorption dehydration processes. It describes how molecular sieves are used to dehydrate natural gas and how their capacity declines over cycles due to loss of structure. Having excess regeneration capacity, or standby time, allows operators to reduce cycle times and extend the life of molecular sieves. The document presents a case study where performance testing revealed capacity would decline faster than designed. Using standby time by reducing cycle times allowed the unit to operate for longer than the planned 3 years before recharge.
Plant Sustainability and Relaibility.pptxssuser61b22e
This document proposes several ideas to improve plant sustainability and reliability at a manufacturing facility. It suggests reducing the closure time for slurry injection nozzles from 72 to 5 seconds to prevent blockages during power issues. It also recommends repairing drainage channels and applying a waterproof coating around a CP lift pit to stop water seepage and ensure lift integrity. Replacing the chipper die plate after each operation is proposed to reduce waste generation and maintain smooth plant operations. Installing a larger condenser for a dow vent collection tank is suggested to properly condense vapors and reduce dow wastage. Additionally, stopping a blended glycol pump and casting water tube well except during required periods as well as stopping an esterifier agitator before
The document describes the design of an integrated forward osmosis-reverse osmosis (FO-RO) system for wastewater treatment and potable water production. It involves a two-stage process where seawater is first diluted using impaired wastewater through an FO membrane. This diluted seawater is then processed through a reverse osmosis membrane to reject salts and contaminants. Material and energy balances are presented to determine flow rates and energy requirements. Key aspects of the process design like membrane area, pump selection, number of membrane modules and vessels are also discussed. Finally, a cost estimation is provided for major equipment like membranes, housings and pumps.
Report on Solution for reduction of cycle time in the manufacturing of Al WheelsLAVA KUMAR ADDEPALLI
The document is a report on reducing the cycle time of the forging process in the manufacturing of aluminum wheels. It analyzes the current forging process and identifies manual spraying as a major time consuming activity. It then proposes a solution to introduce a second automatic spraying system to target the specific point where manual spraying is currently required, in order to eliminate that step and reduce the cycle time by around 50 seconds per wheel. The solution is analyzed and diagrams of the proposed automatic spraying system and its installation in the forging machine are provided.
Mayur Savale is seeking a position that allows him to utilize his skills and contribute to personal and professional growth. He has over 5 years of experience as a Production Engineer at Abhilasha Tex-Chem pvt. ltd., where he has led initiatives to improve product quality, reduce costs and environmental impact. Educationally, he holds a B.E. in Chemical Engineering and conducted a final year project on alternative water treatment using hydrodynamic cavitation. He is pursuing additional process engineering training involving simulation software.
Distillation is one of the widely used separation method in most of the chemical process industries. Improper design
/operation & maintenance leads to various troubles like reduced plant capacity, poor quality of separated products,
high energy (utility) consumption, etc.
DRIP IRRIGATION PIPE INDUSTRY PROJECT...lalwanilisaa
The document summarizes a visit by students to a drip irrigation pipe manufacturing plant. It describes the production process which involves extruding plastic into pipes, adding drippers, quality testing, packaging and shipping. A flow chart outlines the key stages of material preparation, extrusion, cooling, marking, quality control, and packaging. Critical questions are examined about common problems with drip irrigation systems and how to improve their effectiveness and lifespan. Drip irrigation is concluded to be an efficient water delivery method and suggestions are provided to optimize the manufacturing process.
Presentation by Pat Hulme (Sustainable Soil Management, Warren) to a meeting of the Riverina branch of the Australian Society of Soil Science at Yanco Agricultural Institute on 16 August 2013
Irrigation: Improving efficiency in your flood of pivot irrigationCaleb M Carter
This document discusses strategies for improving the efficiency of flood and pivot irrigation systems. It provides information on assessing soil properties, determining water needs, and managing application rates to minimize runoff. Specific recommendations include leveling fields, lining ditches, using gated pipe, and improving irrigation management for flood systems. For pivots, the document suggests monitoring pressure and flow rates, adjusting sprinkler spacing and height, and controlling application amounts based on soil infiltration rates. Regular maintenance and measuring soil moisture and pivot performance are also emphasized for optimizing efficiency.
This document outlines a project to optimize the layout of an NMR LWD laboratory using Lean tools and techniques. It begins with an analysis of the current layout and processes, identifying issues like excessive motion, transportation, defects, and waiting times. Metrics are collected on process times and efficiencies to establish a baseline. Opportunities for improvement are then identified, including designing a new layout to streamline tool flow and reducing non-value-added activities. The objectives are to increase efficiency by 22%, capacity by 23%, and improve safety, quality and cost. Solutions will be implemented through kaizen events, a new layout, 5S techniques, and standardizing processes.
SPB implemented several water conservation measures at its paper machine that reduced fresh water usage. They included recycling vacuum pump cooling water back to the pumps instead of sending it to the ETP. They also reused deculator vacuum pump sealing water by routing it through a cooling tower instead of to the white water tank. These changes eliminated fresh water makeup for the vacuum systems and reduced the overall fresh water usage.
Artificial Lift Screening and Selection - Focus on Reservoir ConsiderationsAndres Martingano
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1. Optimization of Grade Change Process for
Minimization of Down Time:
By:
D K Singhal
Chandpur Enterprises Ltd.,
Sargam Theatre, Chandpur-246725
Dist. Bijnor (U.P.)
Res: Shiv Lok Colony, Siau Road,
Chandpur-246725 Dist Bijnor (U.P.)
INDIA
deveshksinghal@rediffmail.com
deveshksinghal@gmail.com
Abstract:
The present work shows how critical path method (CPM) can be successfully implemented to
reduce the time required for system wash-up during grade changes. It has been observed that after
implementation of CPM activities, there was a reduction of more than 50-60% downtime for
grade change.
1
2. Introduction:
Unlike many paper machines in developed countries, grade change is very common in Indian
mills. Though, many experts are of the opinion that grade changes should be avoided as it is
wastage of time and resources (as a lot of inputs are wasted during the grade change process), yet,
many mills are interested in making different grades of paper just due to economic reasons on a
single paper machine. In this way, for mills producing different grades of paper on a single
machine, quality change costs some additional amount that has to be reduced in order to be
competent enough to stay in the market.
Present Practices:
We can differentiate grade changes in three categories- GSM Change, without any colour or
furnish or shade change; furnish or shade change, with or without GSM change where changes
are minor and trace amounts of previous furnish does not affect the next quality significantly; and
furnish or shade change, with or without GSM change where changes are minor and trace
amounts of previous furnish severely affects the next quality. Where only the GSM has to be
changed, there is not much problem, and speed changes along with change in basis weight valve
opening or steam pressure set point changes can solve the problem. On some machines, GSM
fluctuation can occur during a grade change, but earlier work by the author1-3 shows how such
problems can be solved.
In case of furnish or shade changes, normally, system is drained, filled with water again and
machine is started up with new furnish. If there is a doubt that previous shade and affect the next
quality, the system is drained, filled with water and restarted with water only, for a couple of
minutes, drained again, refilled with water, and then started. This obviously takes longer time. On
a typical paper machine, the time was to the tune of 1.5-2 hours. As the mill started receiving
smaller orders, and longer runs were not possible due to delivery and other constraints it became
necessary to optimize grade changes for quicker and faster grade changes.
Methodology:
Critical path method is a commonly used technique for project optimization where different tasks
are to be completed and some of these are dependent on others. For example, if 10 jobs are to be
done to complete a project, the maximum time required by the project would be sum of time
required for each job. Similarly, the minimum time required to finish the project would be the
maximum of time required by an individual job, provided all jobs are independent. But, in
practical cases, some jobs are dependent on others, as in our case, we cannot fill backwater silo
with fresh water if it has not been drained and cleaned properly.
The use of critical path method was implemented and all the activities were assigned different
codes (alphabets).
Let us see in detail, what happens during a grade change with furnish change-
2
3. Activity Code (Time)
• Stop machine chest agitator. A (0.5)
• Stop machine chest pump. B (1.5)
• Stop Vacuum Pumps. C (0.5)
• Stop Tertiary Centricleaner Pump. D (0.5)
• Stop Secondary Centricleaner pump. E (0.5)
• Stop Fan Pump. F (0.5)
• Stop Pressure Screen. G (0.5)
• Stop Vibrating Screen. H (0.5)
• Drain Back Water Silo. I (12)
• Drain primary centricleaner pit. J (5)
• Drain secondary centricleaner pit. K (4)
• Using hose, clean hydra foils, back water channels, etc. L (8)
• Clean Back Water silo using water hose. M (5)
• Fill water in Back Water Silo. N (11)
• Close Silo Drain Valve. O (0.5)
• Fill water in Primary centricleaner pit. P (5)
• Close Primary centricleaner pit drain valve. Q (0.5)
• Fill water in Secondary centricleaner pit. R (4)
• Close secondary centricleaner pit drain valve. S (0.5)
• Start approach flow in usual fashion. T (13)
In this method, we plot a diagram showing each activity with an arrow, starting each subsequent
activity from the head of its previous activity. The initial diagram looks like as given in fig.1. If
we compare the same with Fig.2, i.e. the plot after optimization, we find that there is a great
potential for washing time minimization. As indicated by the figures, the time saved by
optimization was to the tune of 15-20 minutes.
3
4. Another washing related problem was soon noticed just while the analysis of grade change
process started. It was found that while the backwater silo was being drained off, one person
started cleaning the walls of the same using hose pipe. Having done that, he turned to wire table,
and started cleaning table interiors, hydrafoils, etc. By this time, silo was empty and clean, but
had to be cleaned again using hose as slime detached from foils etc. had entered in silo.
Obviously, the correct practice would have been to clean wire table while the silo is being
drained, and then clean silo, followed by water filling process. Paper machine crew was described
in detail with correct washing sequences, illustrating above example, and observed reduction in
system wash-up time afterward.
Further Improvements:
The critical path method also indicates further optimization opportunities in this area. If we
consider fig. 3, we find that there are some activities, where a faster operation can be done to
further reduce the time required for system washing. In fig.3, activities A, B, C, D are some of
activities the time of which can be reduced easily. Following actions were taken for the same-
1. A second drain line in backwater silo was provided to reduce time in silo draining to
4.5 minutes.
2. A second fill line to back water silo using a separate pump was provided, to reduce
filling time to 5 minutes.
3. Incorporating a practice to drain backwater silo just before switching off the machine
chest pump to save 0.5 minutes in emptying backwater silo.
4. Incorporating a practice to start fan pump even when backwater silo is only 75% full.
This saves nearly one minute, without affecting approach flow performance, as
backwater silo fills up before wet web is taken to press part.
The above actions resulted in a direct saving of nearly 10 minutes, without much of investment or
efforts. Additionally, installation of motorized or pneumatically operated valves is being planned
for drain and fill locations, to further save 2-2.5 minutes. The proposed system can later be
interlocked with solenoid valves and timers to automate the draining-filling process.
4
5. Critical Quality Changes:
The common practice with critical quality changes such as from blue poster to yellow poster, the
normal trend in the mills is to make yellow poster first, so as to minimize loss in system washing.
But in case it has to be done, normally, system is drained, washed, filled with water and started
again with water only for a couple of minutes, drained again, and the cycle is repeated. This
obviously is a more time consuming procedure, and there exists a need to look for a more time
efficient process for such changes. For the same, some modifications were made in approach flow
system-
1. Secondary centricleaner accept was taken to a separate decker mounted over machine
chest, with thick stock to machine chest, or drained for a while during the grade
changes. This eliminated need to clean primary centricleaner reject pit
simultaneously with system washing. Now, system can be washed up without
considering PCC reject pit, and while water is being filled in silo, PCC reject pit is
drained. This way, load on mill drains is reduced, or alternatively silo can be drained
much faster if its drain valve needs to be throttled in case of overloading of mill
drains. Having done that, PCC reject pit is filled with water, and PCC pump is
started. As the decker is already being drained, we can get centricleaner system
properly washed within less time. Secondary and tertiary centricleaner systems are
also cleaned in the same way.
2. It was observed that some of dyes are neutralized with certain chemicals. A detailed
analysis of different dye containing water (coloured backwater) was made and
cleaning was limited to partially draining, filling with water, addition of dye remover
chemicals and then draining reduced the quality change time significantly. In a
typical test case, quality change from deep blue poster (match box) to post office red
poster was completed within 14 minutes (paper to paper). Use of hypo has been tried
and found very useful in some furnishes.
3. Couch broke, which was earlier being taken to decker thickner and then to a separate
broke chest was directed to machine chest. By doing so, quality was not affected as
the machine very good machine runnability, and hence the quantity of couch broke is
very less. Provision was also made to drain the couch broke from near the machine
chest. During a quality change, water is filled in couch pit, and is pumped to drain in
order to quickly and efficiently drain couch pit.
4. A separate tank was provided to hold the back water, with a separate pump from
backwater silo and associated piping. This helped in reduction on sudden loading of
mill drains and hence flooding in machine area. The water contained in this tank is
drained later on as and when possible, without creating shock loads on mill drains
and ETP.
5. Automation process is being implemented with PLC control to speed up the process.
As only timer based control is required, the total cost of implementation is very less,
to the tune of rupees two lacs only. With an estimated 5-9 minute saving in each
quality change and washing process, this amount is expected to have a payback of
approximately 6 months only.
Conclusion:
From the above, it is clear that quality change time can be easily reduced by a significant value.
The basic approach is to reschedule all operations involved, to minimize time taken by individual
operations, and to automate the system washing /draining procedures.
5
6. References:
1. Singhal, D.K., “Cross Direction Profile Unstability: Evaluation & Correction”, IPPTA
14(1):35(2002)
2. Singhal, D.K., “Optimization of Approach Flow for GSM Control”, IPPTA, Convention
Issue: 99 (2003)
3. Singhal, D.K., “ Modeling & Simulation of Approach Flow for GSM Control”, IPPTA J.,
17(1): 75(Jan. 2005)
6