Does proces engineering apply to the precision industry?

Transcription

1 Does proces engineering apply to the precision industry? J.C.M. Kooter November 2014 ECN-L

2 Does process engineering apply to the precision industry? Engineering under pressure at elevated temperatures Hans Kooter 12 November

3 Content 1. ECN Environment & Energy Engineering 2. Process Engineering: Balancing Requirements 3. Process Engineering: Examples from ECN practice 4. Process Engineering approach in Precision Engineering

4 ECN at a glance Mission To develop knowledge and technologies that enable a transition to more sustainable energy systems ECN Focus Areas ECN Offices Netherlands (5) Belgium China 5 Commercial licensing deals per year 600 Employees +/-20 patents a year EUR 80 M annual turnover Solar energy Biomass Policy studies Energy efficiency Wind energy Environment & energy engineering

5 Environment & Energy Engineering: Expanding the envelope Engineering & Realization Engineering Realization Commissioning HAZOP Materials Characterization Failure analysis Product optimization Production technology development Testing & Analysis Corrosion testing Lifetime prediction Materials & Gas analysis Pilot plant operation Environmental Assessment Air quality measurements (PM, NO x, CO, NH 3, BTX, C x H y, ) Emissions modelling Leaching Instrument development

6 1. ECN Environment & Energy Engineering 2. Process Engineering: Balancing Requirements 3. Process Engineering: Examples from ECN practice 4. Process Engineering approach in Precision Engineering?

7 Process Engineering is about: Balance and a total view Process Engineering Look at the complete system Specify functional demands How to verify them at FAT/SAT! Bring balance between the functional demands and the design solution Visualize Using schematic diagram s [PFD, P&ID, ] Communicate Using your visualized stuff Involve specialists in early stage Wat mot er en wat kan er Key challenges Environment Safety Heat and mass balance Flow Pressure Radiation Choice of material Manufacturability Operability Maintenance Yield Dimensions Energy use/saving Operational Cost

8 Process engineers think schematics

9 Result: A complete process design package => Value! Design basis Mass and energy balance Process description Process flow diagrams (PFD s) Process control logic and process control diagrams (PCD s or Logic Schemes) Capital cost estimate Operating cost estimate Piping and Instrumentation Diagrams (P&ID s) Equipment plot plans Utility flow diagrams Equipment lists Equipment sizing and specifications datasheets HAZOP (HAZard and OPerability analysis and documentation) Plant layouts Preliminary process operating manuals (normal operation, shut-down, emergency shut-down)

10 Design solutions are determined by material properties and manufacturability

11 Integral approach is key in dealing with challenges Engineering Method Key Issues Purpose of the engineering design process is to create solutions for specific needs Keep looking at the total system. A solution for a partial problem may create a new issue Keep the necessary infrastructure in mind Usage and consumption

12 1. ECN Environment & Energy Engineering 2. Process Engineering: Balancing Requirements 3. Process Engineering: Examples from ECN practice 4. Process Engineering approach in Precision Engineering?

13 ECN offers all capabilities necessary to turn a concept into a working test installation Multidisciplinary team Process engineering Mechanical engineering Electrical engineering Software engineering Materials science covers the entire engineering process Specification (SRS => URS) Process and system design (Aspen) Safety and risk analysis (HAZID/HAZOP/FMECA) Regulatory compliance (CE: Machine directive / PED / ATEX / EMC) Detailed engineering (3D-CAD, ANSYS) Procurement & realization Commissioning & acceptance (FAT, SAT)

14 Our added value comes from decades-long experience in serving internal and external clients Example challenges for designing test installations vs operational installations Scale What scale should be chosen for the test installation to be representative for the eventual operational installation? Start-stop cycles Operational installations are designed to be operated continuously for as long as possible. Test installations are started and stopped very frequently. How to deal with additional stress, material requirements etc? Environment How to deal with oxidative/reductive influences, corrosion, high pressure, high temperature,, and still build a costeffective installation?

15 Example 1: Continuous silicon casting equipment ECN Engineering added value Realized a working machine. Challenging process parameters One wafer per second Required T = 1350 C ± 2 C Clean conditions Homogeneous cooling Silicon casting equipment Alternative production process for producing silicon wafers by casting instead of sawing Challenging boundary conditions Accessibility Shielding Gas consumption

16 RGS principle is to make wafers directly from casting instead of cutting from an ingot RGS casting principle Equipment in operation & End product

17 Original design gave rise to a number of issues Original design Issues with original design Accessibility Scalability Flexibility Volume Argon consumption Footprint

18 Redesign inspired by critical consideration of energy balance and thermal design Redesign based on casting chamber volume reduction Substrate temperatures 1350 C at casting 1000 C at pre-heating Max ΔT over crosssection: ±2 C

19 First calculations revealed a temperature skew Temperature distribution over substrate surface Heat flow analysis

20 Solution: Go for symmetry!

21 Example 2: MILENA Gasifier MILENA gasification technology Key advantages Full feedstock conversion High conversion efficiency Producer gas Low nitrogen High methane High BETX

22 Problem: Material stresses Solution: Thermal redesign (not: material selection) MILENA process challenge Challenging process Indirect gasification Distinct temperature regimes Material stresses Integration Expansion Insulation Geleidend Isolerend Solution: Use thermal properties of bed material (sand)

23 1. ECN Environment & Energy Engineering 2. Process Engineering: Balancing Requirements 3. Process Engineering: Examples from ECN practice 4. Process Engineering approach in Precision Engineering?

24 Integral approach leads to solutions that do not seem to have a direct relation to the problem RGS Silicon casting machine Problems Argon consumption Energy consumption Temperature profile Volume Solutions Smaller dimensions Less mass Symmetry MILENA gasifier Problems Different temperature regimes Material constraints (expansion) Temperature/heat Solution Heat transfer redesign Thermal properties of bed material

25 And would this work for the precision industry? Process engineering Integral approach Solving problems, not creating new ones Cost effective solutions Want to know more? Visit us: Booth 131 ECN Eindhoven ECN Petten

26 Thank you More information: ECN Environment & Energy Engineering Hans Kooter Senior Manager Engineering Westerduinweg LE Petten The Netherlands T: kooter@ecn.nl

27 ECN Westerduinweg 3 P.O. Box LE Petten 1755 LG Petten The Netherlands The Netherlands T F info@ ecn.nl ECN-L Fout! Geen tekst met de opgegeven stijl in het document. 3