38 results on '"Christian Bramsiepe"'
Search Results
2. Using design spaces for more accurate cost estimation during early engineering phases
- Author
-
Christian Post, Gerhard Schembecker, Christian Bramsiepe, and Niklas Wentingmann
- Subjects
Estimation ,Cost estimate ,Process (engineering) ,Computer science ,General Chemical Engineering ,02 engineering and technology ,General Chemistry ,Variance (accounting) ,021001 nanoscience & nanotechnology ,Reliability engineering ,Task (computing) ,020401 chemical engineering ,Work (electrical) ,Range (aeronautics) ,Investment cost ,0204 chemical engineering ,0210 nano-technology - Abstract
The main benefits expected from module-based plant design are shortened planning periods and increased planning as well as cost estimation accuracy during early engineering phases. Most of the existing approaches require equipment module databases. However, overall equipment module databases do still not yet exist. Even though these databases will be available, they will most likely not contain operable equipment modules for any process task. Thus, the objective of this work is to increase the accuracy of investment cost estimation without the need of equipment module databases, which is exemplified for plate as well as shell and tube heat exchangers. Instead of selecting one equipment module from an existing module database for a certain process task, all operable equipment modules are generated by determining design parameter combinations, which are located inside the design space and thus fulfill all operating constraints. Tailor-made equipment design is not needed in any step. The detailed investment cost estimates of all operable equipment modules are used to determine the range of possible investment cost. The variance of the investment cost estimates determined is equal or less than half of the error of conventional preliminary investment cost estimation in case of 54% of the industrial process tasks.
- Published
- 2020
3. Generation of an equipment module database — A maximum coverage problem
- Author
-
Peer Sander, Martin Eilermann, Gerhard Schembecker, Christian Bramsiepe, and Constantin Schach
- Subjects
Database ,Computer science ,General Chemical Engineering ,Maximum coverage problem ,media_common.quotation_subject ,02 engineering and technology ,General Chemistry ,021001 nanoscience & nanotechnology ,computer.software_genre ,Facility location problem ,020401 chemical engineering ,Quality (business) ,0204 chemical engineering ,0210 nano-technology ,Plant design ,Greedy algorithm ,computer ,Lead time ,media_common - Abstract
Current challenges for (bio-)chemical industry require shorter project lead times. To reduce the lead time, the concept of module-based plant design was developed. Suitable equipment modules are selected from an equipment module database instead of time-consuming tailor-made equipment design. The quality of module-based plant design strongly depends on the quality of the equipment module database. An equipment module database should contain the least number of equipment modules covering as many industrial applications as possible. Hence, the generation of an equipment module database is a maximum coverage problem known from other disciplines, such as facility location. Within this work, the corresponding maximum coverage problem is formulated and solved by a randomized greedy algorithm. The approach for the generation of an equipment module database presented is exemplarily applied for liquid/liquid heat transfer applications provided by Evonik . It is shown, that less equipment modules are required for the same coverage of applications if the equipment module database is generated based on the maximum coverage problem than based on the existing methodology presented by Eilermann et al. (2017). Additionally, less computational effort is required.
- Published
- 2019
4. Selection of equipment modules for a flexible modular production plant by a multi-objective evolutionary algorithm
- Author
-
Gerhard Schembecker, Christian Becker, Christian Bramsiepe, Matthias Schröder, and Heiko Radatz
- Subjects
Computer science ,business.industry ,020209 energy ,General Chemical Engineering ,Evolutionary algorithm ,Window (computing) ,02 engineering and technology ,Modular design ,Investment (macroeconomics) ,Computer Science Applications ,Reliability engineering ,020401 chemical engineering ,Work (electrical) ,0202 electrical engineering, electronic engineering, information engineering ,Production (economics) ,0204 chemical engineering ,business ,Realization (systems) ,Selection (genetic algorithm) - Abstract
In this work an approach to select equipment modules for a flexible modular production plant at low investment costs using a multi-objective evolutionary algorithm is introduced. Thereby, a good determination of the plant`s overall operating window is of utmost importance. A styrene production plant serves as case study to evaluate the equipment module selection approach, to analyze the resulting compromise solutions as well as the flexible modular equipment sets with low investment costs. It is for example possible to achieve an 11-fold enlarged operating window for 50% higher investment costs compared to the conventional design. Thus, this work presents an important step towards the realization of modular production plants.
- Published
- 2019
5. Approach for the characterization of industrial process tasks as basis for the generation and application of an equipment module database
- Author
-
Gerhard Schembecker, Christian Bramsiepe, Stephan Leufke, Martin Eilermann, Alexander Tebbe, and Dorothea Schwarz
- Subjects
Measure (data warehouse) ,Similarity (geometry) ,Database ,Cover (telecommunications) ,Process (engineering) ,Computer science ,Applied Mathematics ,General Chemical Engineering ,media_common.quotation_subject ,02 engineering and technology ,General Chemistry ,Reuse ,021001 nanoscience & nanotechnology ,computer.software_genre ,Industrial and Manufacturing Engineering ,Range (mathematics) ,020401 chemical engineering ,Quality (business) ,0204 chemical engineering ,0210 nano-technology ,computer ,Condenser (heat transfer) ,media_common - Abstract
Module-based plant design opens up the opportunity for the (bio-)chemical industry to reduce lead times, which is crucial for future competitiveness. Equipment modules are designed once such that they can cover a wide range of process tasks and conditions. The time-consuming equipment design step is replaced by selecting the most suitable equipment module from an equipment module database so that engineering work is reused. It is the aim of this work to develop a structured approach for the determination of features to characterize industrial process tasks. On the one hand, these characteristic features determined are required for the generation of an equipment module database based on cluster analysis of industrial process tasks (Eilermann et al., 2017). On the other hand, the characteristic features are a measure for similarity of process tasks and support the selection of the same equipment module for similar tasks. Thereby, reuse of engineering is enabled. The approach for the determination of characteristic features presented is based on those used in data mining, whereas the quality of the characteristic features is traded off against the computational effort required. The approach developed is exemplarily applied to industrial liquid/liquid heat exchanger and condenser tasks kindly provided by Evonik.
- Published
- 2018
6. A general approach to module-based plant design
- Author
-
Martin Eilermann, Heiko Radatz, Christian Bramsiepe, Christian Post, and Gerhard Schembecker
- Subjects
Structure (mathematical logic) ,Selection (relational algebra) ,010405 organic chemistry ,Computer science ,General Chemical Engineering ,Context (language use) ,02 engineering and technology ,General Chemistry ,Variance (accounting) ,Work in process ,01 natural sciences ,0104 chemical sciences ,Open research ,020401 chemical engineering ,Work (electrical) ,Modular programming ,Systems engineering ,0204 chemical engineering - Abstract
Increasing economic challenges lead to the need for faster plant design in process industry. In this context, a promising approach is module-based plant design. Thereby, for the accomplishment of the required design tasks modules are selected from databases and configured instead of time-consuming and tailor-made plant design. Within this work, a general approach to module-based plant design is introduced and illustrated based on an example. To structure the design procedure different types of modules are defined for different design tasks: PFD, P&ID, Equipment and 3D Layout. Additionally, module selection can be performed at different Levels of Aggregation to cope with the high variance of applications. This enables module selection and configuration avoiding time-consuming, tailored modifications. Since modules are unmodifiable and project-independent, the module-based plant design approach presented is based on a consistent module definition. This work provides a framework to integrate some of the existing modularization approaches into a general module-based plant design approach. However, most often new approaches are necessary to accomplish the design tasks within the presented module-based plant design approach. Thus, this work also identifies open research gaps that need to be filled by future research.
- Published
- 2018
7. Lead time estimation for modular production plants
- Author
-
Stefan Sievers, Marcel Franzen, Tim Seifert, Christian Bramsiepe, and Gerhard Schembecker
- Subjects
Production line ,Engineering ,business.industry ,General Chemical Engineering ,02 engineering and technology ,General Chemistry ,Modular design ,021001 nanoscience & nanotechnology ,Investment (macroeconomics) ,Reliability engineering ,Reduction (complexity) ,020401 chemical engineering ,Modular programming ,Systems engineering ,Factory (object-oriented programming) ,Production (economics) ,0204 chemical engineering ,0210 nano-technology ,business ,Lead time - Abstract
Modular plant design is an approach for making chemical production more flexible and more efficient. Different approaches for modular plant design have been developed, for example in the CoPIRIDE or F3 factory project. They have in common, that lead time reductions for modular equipment are expected e.g. by utilizing design repetition or parallelization of preassembly of modules. To support the decision for or against a modular concept, besides cost effects possible lead time changes compared to conventional concepts should be anticipated in early economic evaluations already. In this article, a lead time estimation method will be presented that correlates project costs and project durations and can be applied to modular and non-modular plants enabling comparative studies. An example from a previous paper was used to investigate the impact of modularization on lead time. It includes modular production lines and a non-modular backbone facility that provides energy and utility supply. A range of investment sizes (FCI of 3–95 mio. €) was investigated and compared with a conventional reference plant. Total lead time reduction was in the range from 2.6 to 5.5 month depending on investment size. For a more significant impact on the lead time the modularization approach needs to be modified by also applying modular design to the backbone facility. In this case depending on investment size total lead time reduction would be between 3.9 and 18.7 months representing a very significant reduction of 23%–60% compared to the lead time of the conventionally designed reference plant. This is considered as the maximum expectable lead time reduction that can be achieved through modular plant design. This reduction would represent a major potential for speeding up construction of chemical plants.
- Published
- 2017
8. New process function-based selection and configuration methodology for Process Equipment Assemblies (PEAs) exemplified on the unit operation distillation
- Author
-
Stephanie Rech, Marcus Grünewald, Maria Polyakova, David Harding, Dominik Nowara, and Christian Bramsiepe
- Subjects
Flowchart ,business.industry ,Computer science ,Process Chemistry and Technology ,General Chemical Engineering ,media_common.quotation_subject ,Process (computing) ,Energy Engineering and Power Technology ,General Chemistry ,Abstract process ,Unit operation ,Industrial and Manufacturing Engineering ,law.invention ,law ,Fractionating column ,Process engineering ,business ,Function (engineering) ,Distillation ,Block (data storage) ,media_common - Abstract
Process Equipment Assemblies (PEA) are pre-designed equipment sets which are selected instead of time-consuming tailor-made design. This paper introduces a new method for the selection and configuration of PEAs exemplified on the unit operation distillation. First step of the new methodology is the selection of the most suitable technology applying matching matrices. The matching matrix required for selecting a suitable distillation technology is introduced. Next a process function-based planning approach is executed using so called master block flowcharts (MBF). These technology specific flowcharts contain all possible process functions required for any potential separation task and contain the technology specific main function and technology independent process functions. Considering process boundary conditions and functions already available in the infrastructure, the MBF is reduced to the functions required for the process. Next, concrete PEAs are selected starting with the main function where the separation of the fluids takes place using the PEA operating range as the main selection criterion. A tool required to determine the operating range of a distillation column is demonstrated. Finally, the PEAs for auxiliary functions are selected from a databank.
- Published
- 2021
9. Generation of an equipment module database for heat exchangers by cluster analysis of industrial applications
- Author
-
Christian Bramsiepe, Christian Post, Dorothea Schwarz, Gerhard Schembecker, Martin Eilermann, and Stephan Leufke
- Subjects
Engineering ,Database ,business.industry ,Applied Mathematics ,General Chemical Engineering ,Process (computing) ,Sobol sequence ,02 engineering and technology ,General Chemistry ,021001 nanoscience & nanotechnology ,computer.software_genre ,Industrial and Manufacturing Engineering ,Set (abstract data type) ,020401 chemical engineering ,Heat exchanger ,Heat transfer ,Modular programming ,0204 chemical engineering ,0210 nano-technology ,Cluster analysis ,business ,computer ,Shell and tube heat exchanger - Abstract
Module-based plant design opens up the opportunity for the (bio-)chemical industry to reduce lead times, which is crucial for future competitiveness. Equipment modules are designed once such that they can cover a wide range of process applications and conditions. The time-consuming equipment design step is replaced by selecting the most suitable equipment module from an equipment module database so that engineering work is reused. Although of central importance in module-based plant design, an applicable equipment module database has not been developed, yet. Therefore, it is the aim of this work to develop a methodology for the generation of shell and tube heat exchanger modules for an equipment module database. Existing industrial heat transfer applications are grouped by a hierarchical clustering algorithm. For each cluster of applications a representative heat exchanger is selected. A set of possible representatives is generated in a Sobol sequence from which a heat exchanger is selected to be the representative that covers most of the applications inside the cluster considered. The representative heat exchangers are stored in the equipment module database. The resulting 17 heat exchanger modules can cover 59% of the considered industrial applications despite their considerable diversity regarding conservative operating constraints.
- Published
- 2017
10. Design of equipment modules for flexibility
- Author
-
Heiko Radatz, Gerhard Schembecker, Matthias Heitmann, Johannes Martin Elischewski, and Christian Bramsiepe
- Subjects
Flexibility (engineering) ,Engineering ,business.industry ,Applied Mathematics ,General Chemical Engineering ,Window (computing) ,Control engineering ,010103 numerical & computational mathematics ,02 engineering and technology ,General Chemistry ,Modular design ,01 natural sciences ,Industrial and Manufacturing Engineering ,Reliability engineering ,Rule of thumb ,020401 chemical engineering ,Heat exchanger ,Key (cryptography) ,Production (economics) ,Point (geometry) ,0204 chemical engineering ,0101 mathematics ,business - Abstract
A modular production plant consists of predefined apparatuses with a fixed design, called equipment modules. Selecting the equipment module with the appropriate suitable capacity to compensate fluctuations in production rate is one of the key challenges in module-based plant design. The equipment module’s operating window needs to fit and determines the point in time when a capacity expansion is required so that the operating window of the equipment module also affects a capacity expansion strategy. In order to avoid an unnecessary use of multiple apparatuses in parallel, equipment modules should be developed specifically for a large operating window in contrast to conventionally designed equipment. Therefore, an approach is required to design equipment modules for flexibility in production rate. In this work a method to design equipment modules for flexibility based on a global sensitivity analysis and the deduction of design rules of thumb is introduced. This method is applied to the design of a liquid/liquid heat exchanger without phase change. The resulting design for flexibility is compared to the conventional design with regard to the operating window and investment as well as operating costs. It is shown that for 14% higher annual costs a four-fold operating window can be obtained. This presents an important step towards increasing the competitiveness of modular production plants.
- Published
- 2017
11. Framework to decide for an expansion strategy of a small scale continuously operated modular multi-product plant
- Author
-
Gerhard Schembecker, Stefan Sievers, Matthias Heitmann, Christian Bramsiepe, and Thomas Huhn
- Subjects
Production line ,Engineering ,010405 organic chemistry ,business.industry ,Process Chemistry and Technology ,General Chemical Engineering ,Energy Engineering and Power Technology ,Context (language use) ,02 engineering and technology ,General Chemistry ,Modular design ,Investment (macroeconomics) ,01 natural sciences ,Industrial engineering ,Industrial and Manufacturing Engineering ,Continuous production ,0104 chemical sciences ,Production planning ,020401 chemical engineering ,Scalability ,Production (economics) ,0204 chemical engineering ,business - Abstract
Continuously operated multi-product plants enable an efficient and flexible production of new products. As a future plant concept, a modular design allows the possibility of a stepwise capacity expansion when market demand is increasing. Choosing the right plant capacity combined with a suitable expansion strategy is a key challenge in this context. Therefore, additional costs for expansion have to be balanced against an achievable economic performance and a reduction of investment risk. In this work a framework to evaluate the production capacity of a continuously operated modular multi-product production line for a production line wise capacity expansion will be presented. As a result, a decision tree analysis integrating production planning by a capacitated lot sizing method is introduced to evaluate the economic performance of plants with different capacities in an uncertain market. The framework is applied for a case study considering a continuous production of a set of three different products. As a key result it can be said that the investment risk can be reduced by applying smaller scale modular production lines. However, the low scalability of investment costs of a small scale production line negatively affects an economic expansion strategy.
- Published
- 2017
12. Planungsansatz für modulare Anlagen in der chemischen Industrie
- Author
-
Norbert Kockmann, Nicolai Krasberg, Christoph Fleischer-Trebes, and Christian Bramsiepe
- Subjects
020401 chemical engineering ,010405 organic chemistry ,General Chemical Engineering ,02 engineering and technology ,General Chemistry ,0204 chemical engineering ,01 natural sciences ,Industrial and Manufacturing Engineering ,0104 chemical sciences - Abstract
Modulare Produktionsanlagen werden bei der Planung von neuen Anlagen in Betracht gezogen, sobald diese schnell geplant werden und den Charakter von wandlungsfahigen, flexiblen Anlagen mit sich bringen sollen. Hier wird ein modulbasierter Planungsansatz vorgestellt, mit dessen Hilfe die Planung von neuen, modular aufgebauten Anlagen strukturiert und zeiteffizient durchgefuhrt werden kann. Dabei werden alle zum Bau benotigten Dokumente von Modulen in einer Process Equipment Design Dokumentation hinterlegt, die projektubergreifend zur Wiederverwendung zur Verfugung steht.
- Published
- 2017
13. Fixed capital investment estimation for modular production plants
- Author
-
Stefan Sievers, Marcel Franzen, Gerhard Schembecker, Tim Seifert, and Christian Bramsiepe
- Subjects
Engineering ,business.industry ,Applied Mathematics ,General Chemical Engineering ,Financial risk ,02 engineering and technology ,General Chemistry ,Modular design ,021001 nanoscience & nanotechnology ,Investment (macroeconomics) ,Industrial and Manufacturing Engineering ,Manufacturing engineering ,Economies of scale ,020401 chemical engineering ,Modular programming ,Fixed investment ,Systems engineering ,Production (economics) ,Factory (object-oriented programming) ,0204 chemical engineering ,0210 nano-technology ,business - Abstract
Modular plant design is an approach for making chemical production more flexible and more efficient. Different approaches for modular plant design have been developed, for example in the CoPIRIDE or F³ factory project. They have in common that reductions in design and construction expenses for modular equipment and its assembly are expected e.g. by preassembly of modules in a workshop under controlled conditions resulting in less field work on the construction site for erection. However, the main disadvantage of the modular approach is the loss of economy of scale. Thus, the effective impact of the modular concept concerning the fixed capital investment has to be investigated. In this article, a new approach for estimating fixed capital investment of modular production plants will be presented and applied using a generic example. Based on the results we expect that positive effects through modularization on engineering and construction costs can nearly compensate the loss of economy of scale. In the investigated example investment costs of the modular plant are 12% higher than for the comparable conventionally built plant. Such increase could allow other effects that are attributed to the modular concept to be employed to advantage. That would be an economic improvement and a reduction of investment risk in view of the modular plant’s life cycle.
- Published
- 2017
14. Modules in process industry − A life cycle definition
- Author
-
Norbert Kockmann, Katrin Kössl, Christian Bramsiepe, Lukas Hohmann, and Gerhard Schembecker
- Subjects
Engineering ,Standardization ,business.industry ,Process (engineering) ,Process Chemistry and Technology ,General Chemical Engineering ,Energy Engineering and Power Technology ,02 engineering and technology ,General Chemistry ,Reuse ,Modular design ,Work in process ,021001 nanoscience & nanotechnology ,Industrial and Manufacturing Engineering ,Product lifecycle ,020401 chemical engineering ,Systems engineering ,0204 chemical engineering ,0210 nano-technology ,business ,Computer-aided engineering ,Lead time - Abstract
The chemical and biochemical industry has to face the challenges of globalization, short product cycle times and volatile markets. Therefore, the lead time of development projects has to be shortened. Modules and module-based plant design are widely discussed to enable shorter time-to-market by reuse of engineering effort and standardization. In this paper general requirements on modules in process engineering and modules for particular applications in the chemical and biochemical industry are reviewed. This includes the impact of modules on the planning process and examples of realized modular equipment concepts. Based on this, a general terminology definition of ‘modules’ and of specific module types for the process industry is presented, whereas modules on various ‘aggregation levels’ are accounted. A ‘block representation frame’ stores information and tracks information fluxes along the whole process and plant life cycle and on different ‘realization levels’ from laboratory studies over miniplant validation to production plant design and operation.
- Published
- 2017
15. Safety-Lifecycle of Modular Process Plants - Information Model and Workflow
- Author
-
Stefanie Szmais, Christian Schäfer, Niclas Krink, Wolfgang Welscher, Anselm Klose, Leon Urbas, and Christian Bramsiepe
- Subjects
Flexibility (engineering) ,021110 strategic, defence & security studies ,Operability ,Hazard and operability study ,Process (engineering) ,business.industry ,Computer science ,0211 other engineering and technologies ,Process design ,02 engineering and technology ,Modular design ,Workflow ,020401 chemical engineering ,Information model ,Systems engineering ,0204 chemical engineering ,business - Abstract
With modularization of modern process plants, an acceleration in design and engineering is achieved. This development also affects the safety assessment and changes the workflow. Compared to conventional process plants this is expressed especially in regards to store and exchange safety related information between manufacturer and owner/operator. Current risk-assessment techniques fall short to support the advantages of modular process design and production due to the lack of flexibility, as well as missing methods for transformation and transportation of information. To compensate this, current models of safety analysis methods, especially HAZOP (Hazard and Operability) studies, are analyzed and extended. Focus of the analysis is the reuse and integration of previous knowledge similar to the method of the modularization. This research presents a workflow to close the gaps of current risk analysis to meet the changing requirements of modularization. This is done by creating an interface for connecting different HAZOP studies. The specifications are represented in an information model. The concepts of the workflow have been shown on exemplary HAZOP studies.
- Published
- 2019
16. Methodology for evaluating modular production concepts
- Author
-
Gerhard Schembecker, Christian Bramsiepe, Stefan Sievers, and Tim Seifert
- Subjects
Flexibility (engineering) ,Engineering ,010405 organic chemistry ,business.industry ,Process (engineering) ,Applied Mathematics ,General Chemical Engineering ,Supply chain ,02 engineering and technology ,General Chemistry ,Modular design ,01 natural sciences ,Industrial and Manufacturing Engineering ,0104 chemical sciences ,020401 chemical engineering ,Need to know ,Systems engineering ,Factory (object-oriented programming) ,Production (economics) ,0204 chemical engineering ,Process simulation ,business - Abstract
A more flexible and efficient production of chemicals is a requirement for further strengthening the competitiveness in the chemical industry. An approach proposed to achieve this is modular plant design. It offers new opportunities for the supply chain and combines production flexibility and efficiency. However, modular facilities are expected to be built at comparably small scales and loss of economy of scale is a major concern. There is a need to know under which conditions a modular plant design is a beneficial option. Addressing this it would be helpful to have a methodology that includes modeling of production scenarios in a holistic way including supply chain and process simulation and thus allowing a meaningful evaluation. For that reason we developed such a methodology, using the F3 factory concept as an example for modular plant design. Demonstrating the methodology's feasibility an exemplary implementation in a software tool was established enabling comparative simulation and evaluation of batch, continuous and the modular F3 factory production. As unique feature supply chain and process simulation is combined in a single software implementation allowing for statistical analysis to automatically evaluate the economic performance of production concepts under different boundary conditions of the process and the supply chain. The incorporation of those boundary conditions is usually not part of process simulation and goes beyond state of the art approaches. In this paper, the methodology implemented will be presented and the application will be demonstrated using two production scenarios as examples. For the examples investigated, it was found that compared to the conventional production concept the modular F3 factory concept is economically robust concerning the choice of design capacity with regard to diverse market conditions.
- Published
- 2016
17. Synthesis of batch heat exchanger networks utilizing a match ranking matrix
- Author
-
Christian Dowidat, Marc Kalliski, Christian Bramsiepe, and Gerhard Schembecker
- Subjects
Engineering ,Engineering drawing ,Matching (graph theory) ,business.industry ,020209 energy ,Process (computing) ,Energy Engineering and Power Technology ,02 engineering and technology ,Industrial and Manufacturing Engineering ,Matrix (mathematics) ,Ranking ,Heat exchanger network synthesis ,Heat exchanger ,Process integration ,0202 electrical engineering, electronic engineering, information engineering ,Process engineering ,business - Abstract
Direct heat exchanger network synthesis for continuous processes based on pinch methodologies benefits from its intuitiveness and simplicity. The challenge in synthesizing direct heat exchanger networks in batch processes is to handle many small heat streams to form an economic heat exchanger network. In this publication, a new approach for synthesis of direct heat exchanger networks is presented and compared to existing approaches described in literature. Within the new approach a match ranking matrix is utilized to prioritize stream combinations which exhibit the largest potential for cost effective installation instead of matching the streams by their temperature. Thereby, possible loss of heat integration potential is accepted. As a result, the following optimization of the heat exchanger network takes less iteration steps compared to stream matching by temperatures. The approach is applied to an example process to show its applicability.
- Published
- 2016
18. Multivariate risk analysis of an intensified modular hydroformylation process
- Author
-
Robert Franke, Gerhard Schembecker, Stefan Sievers, Marc Becker, F. Stenger, Christian Bramsiepe, Markus Priske, Bart Hamers, Johannes Martin Elischewski, and Tim Seifert
- Subjects
Risk analysis ,Engineering ,business.industry ,Process Chemistry and Technology ,General Chemical Engineering ,Financial risk ,Scale (chemistry) ,Energy Engineering and Power Technology ,Process design ,General Chemistry ,Work in process ,Investment (macroeconomics) ,Industrial and Manufacturing Engineering ,Economies of scale ,Risk analysis (engineering) ,Risk assessment ,business - Abstract
Reduction of investment risk is a major challenge in chemical process design. To minimize financial risks a paradigm shift is necessary. Therefore, risk analysis will have to gain importance already during process development. Only in this way can plant designs be identified that cover the expected demand uncertainty at optimal costs. Stepwise expansion is one option to reduce risks as investments can be spread over a certain time period. This allows waiting for more precise market information and adapting production output to changing market development. The drawback of this approach is the loss in economy of scale. Potentially higher investment costs have to be balanced against an achievable risk reduction which makes the integration of risk assessment in process design indispensable. Furthermore, equipment allowing for an efficient numbering up in plant expansion is needed. Here one of the most promising options is the application of intensified equipment. This work shows how process intensified equipment can be used to reduce the investment risk of a large scale hydroformylation plant. Two methods for risk quantification are applied. Both show that investment risk is reduced by numbering up unit operations and adapting their size. Influencing parameters are the cost structure and process boundaries.
- Published
- 2015
19. Sicherheitstechnische Aspekte bei Planung und Bau modularer Produktionsanlagen
- Author
-
Norbert Kockmann, Christoph Fleischer, Christian Bramsiepe, Juri Wittmann, and Thomas Bieringer
- Subjects
Gynecology ,medicine.medical_specialty ,Computer science ,General Chemical Engineering ,medicine ,General Chemistry ,Industrial and Manufacturing Engineering ,Plant safety - Abstract
Die Entwicklung und der Einsatz von modulbasierten Produktionsanlagen wird als Strategie angesehen, um auf wachsende Anforderungen an den weltweiten Chemiemarkt reagieren zu konnen. Bei den neuen Anlagentypen handelt es sich wie bei klassischen Anlagen um ein Arbeitsmittel, das vor dem Gebrauch hinsichtlich der sicheren Benutzung gepruft werden muss. Daher mussen Risikoanalysemethoden identifiziert und effizient angewendet werden, die einen sicheren Betrieb gewahrleisten. Anhand von intra- und intermodularen Sicherheitsbetrachtungen, der Anwendung einer Moduldatenbank sowie der Kategorisierung von Modulen in Betriebsfensterklassen kann der erforderliche Aufwand hin zur sicheren Produktionsanlage reduziert werden. The development and application of module-based production plants is a strategy to respond to ever increasing demands on the global chemicals market. Similar to conventionally planned production plants the new developed plant type must be checked for safe use. Therefore, risk analysis methods have to be identified and applied effectively which ensure a safe operation. By using intra- and inter-modular safety assessments, a module data database and by assigning modules to an operating window the effort for achieving a safe production plant can be reduced.
- Published
- 2015
20. Real option framework for equipment wise expansion of modular plants applied to the design of a continuous multiproduct plant
- Author
-
Gerhard Schembecker, Christian Bramsiepe, Helene Schreider, Stefan Sievers, and Tim Seifert
- Subjects
Flexibility (engineering) ,Production line ,Engineering ,business.industry ,General Chemical Engineering ,General Chemistry ,Modular design ,Investment (macroeconomics) ,Industrial engineering ,Continuous production ,Economies of scale ,Supply and demand ,Modular programming ,Systems engineering ,business - Abstract
As market demand forecasts will become more uncertain in the future it is necessary to develop new methods for plant design. New technologies allow combining the flexibility of a batch plant with the efficiency of a continuous production. To gain even more economic benefit intensified equipment is often designed as a module. The usage of equipment modules allows an easily and efficient increase of capacity. In this way a plant expansion close to the market is possible. Consideration of stepwise plant expansion is often limited to the copying of complete production lines. This approach results in high additional investment costs due to the loss of economy of scale. To overcome the limitations set by economy of scale, an equipment wise expansion strategy should be applied. By debottlenecking the capacity limits of the plant it is possible to adapt plant capacity very close to the changing environment and reduce the additional costs. Therefore, design of a modular plant must be combined with suitable economic evaluation methods for uncertain demand forecasts. In this work a framework for such a design based on predefined and standardized modules will be presented. The framework consists of two stages. The first stage is the selection of possible modular setups and suitable expansion strategies. Next these setups are evaluated in a real option analysis to investigate the economic performance in an uncertain market. The approach will be used to evaluate a multiproduct continuous plant. The main finding is that the economy of the modular plant depends under the given boundary conditions on the equipment item with the highest proportion on total investment costs and a high cost degression exponent.
- Published
- 2015
21. Intensified hydroformylation as an example for flexible intermediates production
- Author
-
F. Stenger, Bart Hamers, Stefan Sievers, Markus Priske, Robert Franke, Marc Becker, Gerhard Schembecker, Phanuel Fakner, Christian Bramsiepe, and Tim Seifert
- Subjects
Engineering ,Leverage (finance) ,business.industry ,Process Chemistry and Technology ,General Chemical Engineering ,Energy Engineering and Power Technology ,Process design ,Control engineering ,General Chemistry ,Net present value ,Industrial and Manufacturing Engineering ,Workflow ,Annuity (American) ,Market development ,business ,Process engineering ,Hydroformylation - Abstract
One of the future challenges for chemical engineering is the design of flexible plants allowing an adaptation of production output to market development. Consequently, the target for the design of new processes must be the identification of equipment allowing such an expansion close to market development. To leverage the full benefit of this approach flexibility analysis has to be integrated into process design workflow. In this article the conventional technology for hydroformylation is compared to an intensified process design. This new design consists of a jet loop reactor followed by a membrane section to separate and recycle the homogenous catalyst. In the first part of the article it will be shown that process intensification leads to a net present value improvement of 30% compared to state of the art hydroformylation at a capacity of 100 kt/a. In the second part suitability of the intensified process for a stepwise plant expansion will be demonstrated. In an expansion scenario with two steps equivalent annual annuity is increased by 5% compared to a one step investment.
- Published
- 2014
22. Heat integration in batch processes including heat streams with time dependent temperature progression
- Author
-
Christian Dowidat, Gerhard Schembecker, Christian Bramsiepe, and Kirsten Ulonska
- Subjects
Lead (geology) ,business.industry ,Process integration ,Process (computing) ,Energy Engineering and Power Technology ,Environmental science ,Thermodynamics ,STREAMS ,Process engineering ,business ,Industrial and Manufacturing Engineering - Abstract
Time Slice Model (TSM) is an existing model suitable to identify the potential for heat integration in batch processes. However, heat streams occurring during a heating or cooling process in a batch vessel cannot be depicted rigorously due to their time dependent temperature profile. Yet such streams can frequently be found in batch processes. Ignoring the temporal dependence of the temperature can lead to inaccurate heat integration targets. In this publication, necessity for the inclusion of time dependent heat streams is illustrated and drawbacks of existing approaches are demonstrated. A methodology for considering heat streams with temperature profiles in TSM is presented and it is demonstrated that introducing additional time slices allow prediction of integration potential without accuracy loss.
- Published
- 2014
23. Information Technologies for Innovative Process and Plant Design
- Author
-
Christian Bramsiepe, Lukas Hohmann, Nicolai Krasberg, Norbert Kockmann, Gerhard Schembecker, and Christoph Fleischer
- Subjects
Engineering ,Process (engineering) ,business.industry ,Project commissioning ,General Chemical Engineering ,Information technology ,Process design ,General Chemistry ,Industrial and Manufacturing Engineering ,Manufacturing engineering ,Container (abstract data type) ,Modular programming ,Systems engineering ,business ,Computer-aided engineering ,Lead time - Abstract
Process and plant design is associated with long lead times from first planning to plant commissioning. Methods to reduce lead time in chemical engineering process and plant design are reviewed. Experiment-based process design methods for small-scale production will be discussed as well as recent approaches for module-based plant design. For both, the required information technologies will be discussed, and an overview will be given about suitable and available software solutions. Finally, an innovative approach to modularization for small-scale continuous container processes will be presented.
- Published
- 2014
24. A Model to Characterize and Predict Fugitive Emissions from Flange Joints
- Author
-
Lukas Pansegrau, Gerhard Schembecker, and Christian Bramsiepe
- Subjects
Materials science ,General Chemical Engineering ,Gasket ,Flow (psychology) ,General Chemistry ,Mechanics ,Flange ,Industrial and Manufacturing Engineering ,Physics::Fluid Dynamics ,Stress (mechanics) ,Petrochemical ,Forensic engineering ,Boundary value problem ,Graphite ,Fugitive emissions - Abstract
The new model describing the gaseous transport through graphite gaskets is based on the assumption of a flow in the transition regime through nano-scale capillaries, using the Maxwellian wall-slip boundary condition for rarefied gases. Together with an earlier published model describing the liquid transport in graphite gaskets, it enables the characterization of fugitive emissions of volatile organic compounds from fluid-charged flange joints in chemical and petrochemical plants as a function of medium properties, pipe pressure, and gasket stress. Additionally, combination of the models allows predicting the emission rates of gases by experiments with liquids as the emitting fluid. Finally, recommendations are made to improve the gaskets with respect to their sealing performance towards gases.
- Published
- 2014
25. Capacity Flexibility of Chemical Plants
- Author
-
Tim Seifert, Stefan Sievers, Gerhard Schembecker, Anna-Katharina Lesniak, and Christian Bramsiepe
- Subjects
Flexibility (engineering) ,Engineering ,business.industry ,General Chemical Engineering ,Chemical plant ,General Chemistry ,Modular design ,Industrial engineering ,Industrial and Manufacturing Engineering ,Numbering ,Work (electrical) ,Risk analysis (engineering) ,Manufacturing ,Modular programming ,Production (economics) ,business - Abstract
In the light of market uncertainties and globalization, the capacity of fast and flexible adaption of a chemical plant to changing market conditions becomes a major necessity in future production scenarios. The capacity flexibility of a plant can be influenced by oversizing and numbering up of unit operations. The additional costs for these measures have to be compensated for by the financial benefit arising from the option to adapt to uncertain market demands. Therefore, the additional costs have to be balanced against the gain in flexibility. In this work, methods for the evaluation of capacity flexibility are adapted from the manufacturing industries to enable a cost-effective design of a modular plant. The evaluation methods are used to select modular plant setups allowing the best compromise between costs and flexibility in different market scenarios.
- Published
- 2014
26. Die 50 %-Idee: Modularisierung im Planungsprozess
- Author
-
Christian Bramsiepe and Gerhard Schembecker
- Subjects
Gynecology ,medicine.medical_specialty ,General Chemical Engineering ,Philosophy ,medicine ,General Chemistry ,Plant design ,Industrial and Manufacturing Engineering - Abstract
Im Rahmen der 50 %-Idee stellt die Modularisierung einen zentralen Ansatz zur Beschleunigung der Projektdurchlaufzeiten dar. In diesem Zusammenhang werden zunachst verschiedene Sichtweisen auf die Modularisierung bei der Planung chemischer Produktionsanlagen beschrieben. Es werden drei Modultypen eingefuhrt und deren Einfluss auf den Planungsprozess dargelegt. Abschliesend werden die Vorteile eines modularisierten Planungsprozesses im Gesamtkonzept der 50 %-Idee diskutiert und erforderliche Forschungsarbeiten umrissen.
- Published
- 2012
27. Small scale, modular and continuous: A new approach in plant design
- Author
-
Tim Seifert, Christian Bramsiepe, Gerhard Schembecker, and Stefan Sievers
- Subjects
Flexibility (engineering) ,Engineering ,Continuous operation ,business.industry ,Process Chemistry and Technology ,General Chemical Engineering ,Time to market ,Scale (chemistry) ,Energy Engineering and Power Technology ,General Chemistry ,Modular design ,Industrial engineering ,Net present value ,Industrial and Manufacturing Engineering ,Production (economics) ,business ,Discounted cash flow - Abstract
Globalization, product diversity, varying customer demands, uncertain markets and shorter product lifetime are new challenges chemical and biochemical companies are facing more and more. As they combine the flexibility of multiproduct batch plants with the efficiency of continuous world scale plants, small scale continuous plants present an alternative production mode suitable to face these challenges. Building these plants from standardized modules can additionally help to reduce time to market and costs. It is the aim of this work to prove the economical advantages of this concept. The investigations are performed on a multiproduct batch plant for the production of four different recombinant proteins. To prove the concept the production in four continuous modular mono-product plants are benchmarked against the base case. Calculating the investment and operating costs of both concepts and comparing them using discounted cash flow analysis proves, that a change from batch to continuous operation results in a more than 30% higher net present value at the end of the operating period. Designing the continuous plants modularly leads to another 35% higher net present value assuming that the construction period can be reduced from three years to one year by this concept.
- Published
- 2012
28. Anforderungsprofil für die skalenübergreifende modulbasierte Prozessentwicklung
- Author
-
Maria Polyakova, Marcus Grünewald, Christian Bramsiepe, and F. Stenger
- Subjects
020401 chemical engineering ,010405 organic chemistry ,General Chemical Engineering ,02 engineering and technology ,General Chemistry ,0204 chemical engineering ,01 natural sciences ,Industrial and Manufacturing Engineering ,0104 chemical sciences - Published
- 2018
29. A model to predict fugitive VOC emissions from liquid charged flange joints with graphite gaskets
- Author
-
Gerhard Schembecker, Christian Bramsiepe, and Lukas Pansegrau
- Subjects
Materials science ,Capillary action ,General Chemical Engineering ,Gasket ,Laminar flow ,General Chemistry ,Flange ,Industrial and Manufacturing Engineering ,Physics::Fluid Dynamics ,Correlation analysis ,Forensic engineering ,Environmental Chemistry ,Graphite ,Composite material ,Fugitive emissions - Abstract
A model to describe the fugitive emission of volatile organic compounds from flange joints is presented. By combination of laminar and capillary flow in a new concept of branching capillaries, this conception increases the prediction accuracy compared to the existing model of linear capillaries. Furthermore a correlation is deduced to describe the capillary diameter as a function of gasket stress using the compression curve of the gasket. A model is developed and experimentally validated, which predicts fugitive emissions from liquid charged flange joints as a function of medium properties, pipe pressure, gasket width and gasket stress. Finally the parameters influencing the emission rate of liquid charged flange joints are discussed and recommendations for fugitive emission reduction are presented.
- Published
- 2010
30. Fugitive Emissions from Liquid-Charged Flange Joints: A Comparison of Laboratory and Field Data
- Author
-
Christian Bramsiepe and Gerhard Schembecker
- Subjects
Air Pollutants ,Mass transport ,Engineering ,business.industry ,Astrophysics::High Energy Astrophysical Phenomena ,Nuclear engineering ,Field data ,Environmental engineering ,Air pollution ,Gas emissions ,General Chemistry ,Flange ,medicine.disease_cause ,Physics::Fluid Dynamics ,Models, Chemical ,Air Pollution ,Chemical Industry ,Mass transfer ,medicine ,Environmental Chemistry ,Fugacity ,Fugitive emissions ,business ,Astrophysics::Galaxy Astrophysics ,Environmental Monitoring - Abstract
Starting from Hagen-Poiseuille's law, we analyzed the parameters influencing fugitive emission rates. It is shown that liquid and gas emissions follow basically different mass transport mechanisms so that mathematical models available for gases are not suitable to calculate liquid emissions. The emission behavior of liquid-charged flange joints is characterized, and a model conception for the observed phenomena is presented explaining the unexpectedly high emissions of liquid-charged flange joints. Against the background of field data, the influence of maintenance on fugitive emmissions is demonstrated, and exchanging old gaskets with high-grade gaskets as a means of emission reduction in old plants is critically scrutinized. A general maintenance plan is proposed as the most effective method for emission reductions.
- Published
- 2009
31. Comparison of Capacity Expansion Strategies for Chemical Production Plants
- Author
-
Heiko Radatz, Gerhard Schembecker, Christian Bramsiepe, and Kevin Kühne
- Subjects
Materials science ,Exploit ,Computer science ,media_common.quotation_subject ,General Chemical Engineering ,02 engineering and technology ,01 natural sciences ,Profit (economics) ,Adaptability ,Industrial and Manufacturing Engineering ,Supply and demand ,Chemical production ,020401 chemical engineering ,Process simulation ,0204 chemical engineering ,media_common ,business.industry ,010405 organic chemistry ,Financial risk ,General Chemistry ,Modular design ,021001 nanoscience & nanotechnology ,Pulp and paper industry ,Reliability engineering ,0104 chemical sciences ,0210 nano-technology ,business - Abstract
Changing market conditions and production requirements in chemical and biochemical industry force engineers to depart from conventional plant design. Adaptability to the market demand, a reduced investment risk and a shorter time-to-market are gaining importance besides technical excellence. A reduced investment risk and an increased adaptability can be achieved by designing smaller plants and use step-wise capacity expansions. The use of modules offers the possibility to reduce the time-to-market. This work introduces an approach to determine the best expansion strategies for modular equipment-wise capacity expansions and compares its results to line-wise capacity expansion strategies and to a conventionally designed plant for a given market demand development using a detailed process simulation. In a case study, the modular equipment-wise expansion strategy offers a 30% lower initial investment risk while increasing the absolute profit up to 40%, although the overall investment increased up to 40% compared to the conventional design. Additionally, an approach to design reactor modules with a larger operating window is proposed and compared in light of an equipment-wise capacity expansion strategy. Two final key statements to exploit the full potential of an equipment-wise capacity expansion are: (a) the determination of operating windows based on process-technological and mechanical operating constraints is a necessity and (b) equipment modules need to be designed for a large operating window to offer a capacity expansion by numbering-up without a gap in the operating window.
- Published
- 2016
32. Selection of Technical Reactor Equipment for Modular, Continuous Small-Scale Plants
- Author
-
Norbert Kockmann, Christian Bramsiepe, Nicolai Krasberg, Thomas Bieringer, and Lukas Hohmann
- Subjects
scale-up ,Engineering ,Bioengineering ,predefined equipment ,lcsh:Chemical technology ,7. Clean energy ,modular plant design ,lcsh:Chemistry ,Chemical Engineering (miscellaneous) ,Production (economics) ,lcsh:TP1-1185 ,Plug flow reactor model ,Selection (genetic algorithm) ,continuous processing ,business.industry ,Process Chemistry and Technology ,Scale (chemistry) ,Modular design ,Process conditions ,equipment selection ,lcsh:QD1-999 ,Homogeneous ,SCALE-UP ,Systems engineering ,business - Abstract
Fast process development, flexible production and the utilization of advanced process conditions are the main goals of modular and continuous small-scale plants (MCSPs). A configurable layout of the modules and the use of predefined equipment enable a quick and reliable conceptual process development and scale-up of continuous processes. Therefore, a computer-assisted selection methodology was developed and is presented, which allows the quick selection of plug flow reactor equipment for homogeneous liquid phase reactions. It identifies a favorable technical apparatus and the configuration in the early stages of process development. This can lead to the effective planning and guiding of scale-up experiments and closes the gap between lab and process development.
- Published
- 2014
- Full Text
- View/download PDF
33. Einsatz von modularem Equipment in Wärmeübertragernetzwerken
- Author
-
Christian Bramsiepe, M. Eilermann, T. Gottschalk, and Gerhard Schembecker
- Subjects
Engineering ,020401 chemical engineering ,010405 organic chemistry ,business.industry ,General Chemical Engineering ,02 engineering and technology ,General Chemistry ,0204 chemical engineering ,business ,01 natural sciences ,Industrial and Manufacturing Engineering ,0104 chemical sciences - Published
- 2016
34. The TOP-REF Approach for Identification of Critical Process Parameters for Process Monitoring and Optimization
- Author
-
Heiko Radatz, T. Hellenkamp, Christian Bramsiepe, and Gerhard Schembecker
- Subjects
Identification (information) ,Computer science ,business.industry ,General Chemical Engineering ,Process (computing) ,Process optimization ,General Chemistry ,Process engineering ,business ,Industrial and Manufacturing Engineering - Published
- 2016
35. Low-cost small scale processing technologies for production applications in various environments-Mass produced factories
- Author
-
Stefan Sievers, Christian Bramsiepe, B Muster, Marieke E. Bruins, Georgios D. Stefanidis, H Schnitzer, Johan P.M. Sanders, Dionisios G. Vlachos, Tim Seifert, Gerhard Schembecker, and Christoph Brunner
- Subjects
Engineering ,microchannel reactor ,General Chemical Engineering ,Time to market ,Biobased Chemistry and Technology ,Energy Engineering and Power Technology ,transportation fuels ,microreactor stacks ,Raw material ,Industrial and Manufacturing Engineering ,Process integration ,catalytic pyrolysis ,Process engineering ,reactive distillation ,VLAG ,fischer-tropsch synthesis ,Waste management ,business.industry ,Process Chemistry and Technology ,General Chemistry ,Energy consumption ,hydrogen-production ,Economies of scale ,Biofuel ,microwave-assisted pyrolysis ,Food processing ,bio-oil ,business ,Renewable resource ,oxygenated hydrocarbons - Abstract
The requirements for chemical and food production technologies will change in the future as a result of shorter time to market and increasing market volatility. Especially the rising use of renewable resources will require the implementation of flexible and fast to install small-scale production technologies. The increasing number of necessary apparatuses and their distributed operation, however, will constitute major challenges, both economically and procedurally. The proposed solution to face the economic challenge is modularization and standardization. For food production, dewatering represents a key issue. Thus, biomass processing should first be divided into small-scale water separation steps and then into further large-scale processing steps. As dewatering usually happens thermally and heat exchangers often benefit from the economies of scale, heat supply and energy consumption or heat transfer with little capital investment are further issues. Therefore, temperature levels should be decreased and the use of solar heat increased. For the production of biofuels and chemicals from biomass, process integration and process simplification are proposed to improve the efficacy of production equipment and processes. Choosing raw materials with molecular structures, similar to the desired chemical building block, will lower the need for heat exchange and make small-scale manufacturing of fuels and chemicals possible.
- Published
- 2012
36. Design of Equipment Modules Regarding Flexibility
- Author
-
Heiko Radatz, Matthias Heitmann, Christian Bramsiepe, and Gerhard Schembecker
- Subjects
Flexibility (engineering) ,Computer science ,General Chemical Engineering ,General Chemistry ,Industrial and Manufacturing Engineering ,Manufacturing engineering - Published
- 2014
37. Entwicklung einer Methode zur Virusinaktivierung bei niedrigem pH-Wert für kontinuierliche Produktionsprozesse von Antikörpern
- Author
-
Gerhard Schembecker, Christian Bramsiepe, Norbert Kockmann, Martin Lobedann, Safa Kutup Kurt, and Stephan Klutz
- Subjects
Physics ,General Chemical Engineering ,General Chemistry ,Industrial and Manufacturing Engineering - Published
- 2014
38. Flexibles und schnelles Design eines modularen Rohrreaktors
- Author
-
Heiko Radatz, L. Michieleto, Gerhard Schembecker, Matthias Heitmann, and Christian Bramsiepe
- Subjects
General Chemical Engineering ,General Chemistry ,Industrial and Manufacturing Engineering - Abstract
© 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim www.cit-journal.com V2.03 Integration eines Mikroreaktor-basierten MultipurposeAufbaus in eine containerartige Produktionsinfrastruktur Dr. P. Lob (E-Mail: patrick.loeb@imm.fraunhofer.de), Dr. T. H. Rehm, Dr. A. Ghaini, Dr. T. Illg, Dr. J. Lang, Dr. H. Richert Fraunhofer ICT-IMM, Carl-Zeiss-Strase 18–20, D-55129 Mainz, Germany Evonik Industries AG, Rodenbacher Chaussee 4, D-63457 Hanau-Wolfgang, Germany DOI: 10.1002/cite.201450478
- Published
- 2014
Catalog
Discovery Service for Jio Institute Digital Library
For full access to our library's resources, please sign in.