Process Industries 1 E-Book
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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
Of crucial economic and societal importance, process industries transform matter by chemical, physical or biological means. They cover broad fields such as chemistry, oil, pharmacy, metallurgy and agri-food, to name a few. As a result of knowledge exchange between the academic and industrial worlds, Process Industries 1 decrypts the operations and technical management of these industries in order to formulate and manufacture products with use-value, in a sustainable way. Using concrete examples, this book presents the fundamentals for defining the reaction and purification conditions that form the basis of chemical engineering. The unit operations - the technological building blocks of the production units - are the subject of scientific and technical descriptions supplemented by numerous videos. Frameworks, written by well-known specialists, provide a deep understanding of topics related to these themes. Process Industries 1 is intended for students, teachers, professionals and decision-makers interested in learning more about these industries.
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Veröffentlichungsjahr: 2020
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Table of Contents
Cover
Title Page
Copyright Page
Foreword by Laurent Baseilhac
Foreword by Vincent Laflèche
Foreword by June C. Wispelwey
Introduction
1 Industries, Businesses and People
1.1. Manufacturing, process, and service industries
1.2. Founding fathers of the industrial enterprise
1.3. Anatomy of an industrial enterprise
1.4. Industrial strategy: the business plan
1.5. Systemic vision of the enterprise: the enterprise and flows
1.6. The two operating modes of the enterprise: operational and entrepreneurial
1.7. Governance
1.8. Operations abroad
1.9. References
2 Earth, Our Habitat: Products by the Millions, the Need for Awareness
2.1. Population explosion
2.2. Systemic analysis and the concept of a system
2.3. Earth, a complex system
2.4. Awareness, sustainable development
2.5. Products by the millions
2.6. Resource Earth, garbage Earth: towards a circular economy
2.7. Materials science
2.8. Product formulation and engineering
2.9. Product toxicology and ecotoxicology
2.10. Product packaging and ergonomics
2.11. New consumer requirements
2.12. Boxes
2.13. References
3 Designing Chemical Products
3.1. Introduction
3.2. Basic technologies
3.3. Products
3.4. Product design 4.0
3.5. References
4 Chemical Engineering: Introduction and Fundamentals
4.1. Introduction: definitions, history, and challenges
4.2. Fundamentals of chemical engineering
4.3. Box
4.4. References
5 Chemical Engineering: Unit Operations
5.1. Distillation
5.2. Fluid-solid mechanical separations
5.3. Stirring
5.4. Heat exchangers
5.5. Reactors
5.6. Conclusion
5.7. Boxes
5.8. Glossary
5.9. References
List of Authors
Index
Summary of Volume 2
Other titles from ISTE in Chemical Engineering
End User License Agreement
List of Tables
Chapter 2
Table 2.1. Simplified systemic analysis of a city: inputs and outputs
Table 2.2. Applications of virgin plastics
Table 2.3. Steps of the “product engineering" methodology proposed by Cussler an...
Chapter 3
Table 3.1. History of Aspirin
®
Chapter 4
Table 4.1. Conductivities of matter (Pick’s law), heat (Fourier’s law), and mome...
Chapter 5
Table 5.1. Reynolds number and fall velocity (the particle Reynolds number as ca...
Table 5.2. Power and pumping numbers of various impellers in the turbulent regim...
List of Illustrations
Chapter 1
Figure 1.1. Portraits of the fathers of the modern enterprise (from left to ...
Figure 1.2. a) Product life cycle; b) company turnover versus products
Figure 1.3. Principle of strategic analysis of a company (technical aspects)...
Figure 1.4. Systemic vision of the enterprise
Figure 1.5. The enterprise and its flows
Figure 1.6. Schema of the ISO 26000 standard
Chapter 2
Figure 2.1. Our habitat as seen from space. For a color version of this figu...
Figure 2.2. Population explosion
Figure 2.3. Population change by country by 2050. For a color version of thi...
Figure 2.4. Estimated World Population in 2100: Population Growth by Region....
Figure 2.5. Schematization of a system
Figure 2.6. Water cycle (source: Wikimedia Common4). For a color version of ...
Figure 2.7. Rachel Carson (1907-1964), inventor of sustainability
Figure 2.8. Conceptualization of sustainable development. For a color versio...
Figure 2.9. Sustainability and metrics
Figure 2.10. a) The product as seen by the customer; b) the product seen by ...
Figure 2.11. Resource Earth, garbage Earth. For a color version of this figu...
Figure 2.12. Lifecycle of a product (Dal Pont 2012, p. 244)
Figure 2.13. Example of a Smart City. For a color version of this figure, se...
Figure 2.14. Interconnectivity. For a color version of this figure, see www....
Figure 2.15. The consumer and related services. For a color version of this ...
Figure 2.16. Connected city, a view of central data. For a color version of ...
Figure 2.17. Connected city, a view of central data
Figure 2.18. Everyday connected objects. For a color version of this figure,...
Figure 2.19. Main standards based on applications (source: microcontrollerti...
Figure 2.20. Examples of smart objects in the urban area. For a color versio...
Figure 2.21. Example of communicative street furniture (source: Avestone). F...
Figure 2.22. Some objects in a Smart City. For a color version of this figur...
Figure 2.23. Tools of a Digital City. For a color version of this figure, se...
Figure 2.24. Main challenges of Smart City projects main for the decision-ma...
Figure 2.25. Success factors of a city's transformation. For a color version...
Figure 2.26. Example of the city of Nice
Figure 2.27. Mobile convergence solutions: local communication, weather, tra...
Figure 2.28. Return on Investment (ROI)
Figure 2.29. Key steps in an LCA approach (source: Ecoinvent). For a color v...
Figure 2.30. Coupling process modeling, multiobjective optimization, and mul...
Figure 2.31. Absorption, distribution, metabolization, and excretion (ADME)....
Figure 2.32. Lifecycle of a chemical substance. For a color version of this ...
Figure 2.33. Aquatic food chain and transfer of pollution. For a color versi...
Figure 2.34. Examples of 1D and 2D pharma codes. Note that since February 9,...
Figure 2.35. Examples of UHF and HF RFID tags. The UHF tag has a dipole type...
Figure 2.36. Lifecycle (source: Agathe Pernet). For a color version of this ...
Figure 2.37. Typical feeds for Vegan
®
technology
Figure 2.38. Details of a lipid feed
Figure 2.39. Schematic diagram of Vegan® technology. For a color version of ...
Figure 2.40. Evolution of product quality during various stages of the Vegan...
Figure 2.41. Advantages of HVO product compared to biodiesel (FAME/VOME). Fo...
Figure 2.42. Vegan® process. For a color version of this figure, see www.ist...
Figure 2.43. Schematic diagram of an EquiFlow™ Hy-Tray™ dispenser...
Figure 2.44. 3D view of an EquiFlow™ tray installed in a reactor. For a colo...
Figure 2.45. Representation of the scales involved in product design
Figure 2.46. End use properties resulting from formulation and process imple...
Figure 2.47. Product development process
Chapter 3
Figure 3.1. DuPont business lifecycle over time (source: (Connelly 2006))
Figure 3.2. Scales where chemical product design takes place. For a color ve...
Figure 3.3. Chemical products in raw form and as customer product. For a col...
Figure 3.4. Starch production in the EU in 2016. For a color version of this...
Figure 3.5. Main starch application in 2017. For a color version of this fig...
Figure 3.6. Temperature dependency of starch gelatinization. For a color ver...
Figure 3.7. Examples of the application of gelatin in the food and pharmaceu...
Figure 3.8. Structure of alginic acid. For a color version of this figure, s...
Figure 3.9. Structure of alginate solution with or without calcium
Figure 3.10. Principle production of alginate beads. For a color version of ...
Figure 3.11. 100 years of Aspirin® product design. For a color version of th...
Figure 3.12. Buffer system based on citric acid
Figure 3.13. Coffee-based beverages consumption 2018 in the US (source: Hami...
Figure 3.14. Distribution of coffee consumption in 2018 (source: Hamilton Be...
Figure 3.15. Coffee: from raw material to new design products. For a color v...
Figure 3.16. Cappuccino with and without buffer system
Figure 3.17. Product lifecycle
Figure 3.18. Principle of circular economy
Chapter 4
Figure 4.1. Manufacturing aspirin: chemical version (source: (Mesplède 1995)...
Figure 4.2. Manufacturing aspirin: industrial chemistry version
Figure 4.3. Manufacturing aspirin: chemical engineering version
Figure 4.4. Product tree (source: (Gani 2004))
Figure 4.5. Important figures of fluid mechanics, chemistry, and thermodynam...
Figure 4.6. Players of the young thermodynamic discipline in the first half ...
Figure 4.7. a) Carnot’s drawing of his ideal machine in his book Reflections...
Figure 4.8. Total energy balance for an open system
Figure 4.9. Portraits (from left to right) of Joseph Fourier (by L.L. Boilly...
Figure 4.10. From laminar flow to turbulent flow. For a color version of thi...
Figure 4.11. Portrait of Osborne Reynolds by John Collier, 1904 (source: Wik...
Figure 4.12. Changes in concentrations of reactants and products over time. ...
Figure 4.13. Catalysis promotes a reaction by lowering the energy barrier: E...
Figure 4.14. Various stages of a heterogeneous catalytic process. For a colo...
Figure 4.15. Different types of catalysts (photo by Céline Houriez, 2019). F...
Figure 4.16. Diagram of a pressurized water reactor (PWR) (source: Päris Alm...
Figure 4.17. Illustration of energy balance on an elementary section of an e...
Figure 4.18. (a) Closed stirred reactor; (b) continuous stirred reactor; (c)...
Figure 4.19. Typical process: three inputs and two outputs
Chapter 5
Figure 5.1. Various hydrodynamic lengths/scales in the case of a fluidized b...
Figure 5.2. Simple distillation often used in laboratories (source: H. Padle...
Figure 5.3. Continuous industrial distillation (according to (Humphrey (2001...
Figure 5.4. Representation of vapor-liquid equilibria: a) isobaric diagram; ...
Figure 5.5. McCabe–Thiele method (according to Humphrey (2001)). For a color...
Figure 5.6. Drag coefficient (y axis) depending on the particle Reynolds num...
Figure 5.7. Example of a circular gravity settling tank (source: Anglaret (1...
Figure 5.8. Schematic diagram of a disk centrifuge (source: Anglaret (1998))
Figure 5.9. Notations for a centrifuge
Figure 5.10. Schematic diagram of a cyclone (according to: McCabe and Smith ...
Figure 5.11. Filtration categories by particle size
Figure 5.12. Drum filter (source: Coulson and Richardson (2002))
Figure 5.13. Three main types of flow during agitation (source: Midoux (1996...
Figure 5.14. Tangential impellers (Chemineer): (a) anchor; (b) screw; (c) do...
Figure 5.15. Basic stirred tank
Figure 5.16. Power number of a few impellers depending on the Reynolds numbe...
Figure 5.17. TEMA standard for shell and tube heat exchangers (source: Perry...
Figure 5.18. Typical temperature profiles in heat exchangers: (a) co-current...
Figure 5.19. Nomograms for the calculation of a multitubular exchanger 1 she...
Figure 5.20. “Levenspiel plot” the case of a curve with a minimum. For a col...
Figure 5.21. Calculation and optimization of the overall efficiency from the...
Figure 5.22. Typical residence time distributions. For a color version of th...
Figure 5.23. Classification of equipment and process intensification methods
Figure 5.24. Potential equipment limitations, possible intensification strat...
Figure 5.25. Different modeling scales and simulation in chemical engineerin...
Figure 5.26. Multipurpose reactor used for teaching and research (photograph...
Figure 5.27. Pilot rotary kiln designed for research work (photograph by Pha...
Figure 5.28. Practical work bench for “reactors”: Comparison of conversion r...
Figure 5.29. Practical work bench for “pressure drop” (photograph by Clément...
Figure 5.30. Filter press pilot plant (photograph by Clément Haustant, 2019)...
Figure 5.31. Illustration of the energy balance on an elementary section of ...
Figure 5.32. Illustration of energy balance on an elementary section of the ...
Guide
Cover
Table of Contents
Begin Reading
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In memory of JeanneFor Pascal, Christian and CharlesJean-Pierre Dal Pont
To Annick, Cyril and Jean-LouisMarie Debacq
Series EditorJean-Claude Charpentier
Process Industries 1
Sustainability, Managerial and Scientific Fundamentals
Edited by
Jean-Pierre Dal Pont
Marie Debacq
First published 2020 in Great Britain and the United States by ISTE Ltd and John Wiley 8 Sons, Inc.
Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms and licenses issued by the CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the undermentioned address:
ISTE Ltd
27-37 St George’s Road
London SW19 4EU
UK
www.iste.co.uk
John Wiley & Sons, Inc.
111 River Street
Hoboken, NJ 07030
USA
www.wiley.com
© ISTE Ltd 2020
The rights of Jean-Pierre Dal Pont and Marie Debacq to be identified as the authors of this work have been asserted by them in accordance with the Copyright, Designs and Patents Act 1988.
Library of Congress Control Number: 2020940663
British Library Cataloguing-in-Publication Data
A CIP record for this book is available from the British Library
ISBN 978-1-78630-442-1
Foreword by Laurent Baseilhac
Without doubt, we have entered a new era. The upcoming change seems so significant that there is already talk of a digital revolution. In this context, many questions arise:
– What is the future of the process industry and the future of the talented women and men who are its artisans?
– Will we lose this level of excellence in the field? Or, on the contrary, will we cultivate it by reviving professions and vocations in terms of the challenges we see today?
– Is digital technology a winning bet?
– How are industries preparing for their digital transformation? What are the risks involved?
There are so many thought-provoking new challenges.
Jean-Pierre Dal Pont, Marie Debacq, and their co-authors set out to retrace some industrial trajectories that show that, at different times, industry professionals have had the capacity to overcome the challenges of their time (production, productivity, adaptation to consumption patterns, etc.). The challenges differ today, with societal and environmental markers becoming more and more significant. We understand, through the book, that the answers must probably be sought once again in terms of process engineering technologies, as well as in our ability to renew our management models implemented at the industrial level.
I am sure that readers will share this sense of urgency to tackle all the challenges of the new world. In doing so, we are cultivating a field of expression for our present and future talents and we are working on setting the conditions for a possible reindustrialization.
But let’s not go too far, at the risk of betraying the minds of the authors who, at this stage, seek first to provoke the awakening of consciences; they then agree to give us a few solutions, but above all encourage us to pave paths beyond the narrow boundaries that we often draw out of habit in our professions; all this of course without denying the fundamentals that constitute its foundation.
Dear readers, industrialists, academics, students, and future actors or architects of our process industries, I invite you without further delay to dive into this complete, well-documented work, embellished with top quality industrial testimonies where the authors’ inextinguishable passion for their industry is evident.
This is a way to no longer doubt the meaning of our profession, a tremendous burst of energy that writes the industrial history of our next decade.
Laurent BASEILHAC
Processes Director, Arkema
Digital Manufacturing Manager
Foreword by Vincent Laflèche
When Jean-Pierre Dal Pont asked me to write a foreword for his book, I accepted it with enthusiasm.
Not just out of friendship. We have known each other and have had the opportunity to collaborate for over 15 years. We share the same belief in the importance of strengthening links and exchanges between industrialists, researchers and teacher-researchers, between private research, academic research, and higher education.
As Deputy Director, then Chief Executive Officer of INERIS (Institut national de l ’environnement industriel et des risques), then Chairman of BRGM (Bureau de recherches géologiques et minières), and, since 2016, Director of the École des mines de Paris, I have placed the development of research in partnership with companies at the heart of my strategy, while ensuring that our upstream research activity, funded by public subsidies, constantly feeds the scientific excellence of our teams.
The École des mines de Paris adopted its strategic plan in 2017. A member of the new PSL university (Université Paris sciences et lettres, which from the outset has been among the top 50 of the best universities in the world and the top French university), the school puts scientists and engineers in an environment as close as possible to a research activity. Over 75% of the school’s activity is dedicated to research and only around 25% to teaching. Its ambition is to prepare general engineers capable of making a significant contribution to meet the major challenges of the 21st Century. Ecological transformation, with a particular focus on energy transformation, is clearly a strategic focus. The second area of focus is the digital transformation of companies, with a resolute positioning of project ownership for the school. Since the start of the new school year in September 2019, all our engineering students have common core subjects from the first year, which prepares them for Big Data processing, so as not to use words that sometimes go out of fashion quickly, such as deep learning and artificial intelligence (AI). Ensuring the scientific excellence, in particular mathematical excellence, of our engineering students clearly remains a lasting strategic marker.
The “resolute project ownership” approach means that these tools will subsequently be used in engineering projects, in contact with and paying close attention to industrial partners. The school has a long history of Big Data in geoscience to optimize drilling, whether oil or geothermal. The school was also recognized for the contribution of AI in the detection and treatment of cancers as part of its work with the Institut Curie, which is also a member of PSL. The challenge for our graduates is not only to know how to use these new tools, but also to know how to ask and design the industrial question in the wider framework opened up by these new tools, which requires a sound understanding of technological and industrial reality.
We train non-specialized engineers. For more than two centuries, the mines engineer has indeed had to integrate scientific, economic, and human dimensions, as well as management, security, openness, and solidarity that the beginnings of a professional career “basically” and inevitably inculcate. For this purpose, the school’s training combines the so-called “hard” or engineering sciences, natural sciences, and humanities and social sciences (economics, management, sociology, etc.).
The work of Jean-Pierre Dal Pont and Marie Debacq could not better fit the strategy of the school, and vice versa. The words “theory and practice” have been inscribed on the pediment of our establishment for almost two centuries. Similarly, this work is punctuated and illustrated by concrete cases. This choice can only delight the Director of the École des mines that I am. These concrete cases relate to hot topics, often widely publicized (Smart Citites, plastic recycling, etc.). It is not for the sole purpose of following the news: it is recognition of the fact that we are going through a period where we have ever faster cycles of innovation - driven in particular by the digital revolution - and that we need innovation and new technologies to meet the challenges of sustainable development, but also that these innovations are not necessarily accepted by the general public in our society, where we are seeing trust in the engineer and the expert decrease. The engineer and the scientist must integrate this dimension into their approach. The tools and methods developed in this book perfectly integrate these challenges.
This book therefore not only makes an exciting connection between the challenges of business, research, and higher education, it also opens the reader up more broadly to major societal challenges. It does so at a time when, while ecological and energy transitions are underway, the digital revolution is bringing about profound changes to the conduct of companies and industrial management.
This revolution also has consequences on society and brings its share of fears and fantasies, like those engendered by robotics. This book comes at the right time to help students, teachers, researchers, and professionals in their choices and their reflections concerning a rapidly changing world where science and technology are increasingly essential players in sustainable development.
I highly recommend it!
Vincent LAFLÈCHE
Director
École des mines de Paris
Foreword by June C. Wispelwey
Fifteen years ago, when starting the Society for Biological Engineering of the American Institute of Chemical Engineers (AIChE®), I had the good fortune to meet Jean-Pierre Dal Pont. We talked about the future of the chemical engineering profession and about the influence of advancements in biological engineering, particularly with bio-energy and bio-pharma. We discussed the opportunities for creating new life-saving therapeutic proteins and chemicals produced economically from renewable feedstocks. This was the first of many inspiring conversations we would have regarding the future of chemical engineering. It is not a surprise to me that he wrote this passionate book about the process industries and a vision of its future.
Now is a time of transformation. AIChE has a ground floor view of one aspect that is gaining ground - process intensification and modularization. The effort, led by the AIChE’s RAPID Manufacturing Institute, is dedicated to improving energy efficiency and lowering investment requirements, and removing barriers that have limited deployment of this technology. For example, process intensification can combine steps and lead to lower costs in industries such as oil and gas, pulp and paper, and chemical production. Modularization enables one to add capacity in small increments which are more suited to a manufacturer’s need. The Institute de-risks new technologies in these capital-intensive industries and reduces the ecological footprint.
Another new transformative technology is digitization, or Industry 4.0. There are many aspects of digitization, including the internet of things, smart manufacturing, 3D printing, enhanced or virtual reality, artificial intelligence, big data, robotics, drones and more. These individual technologies are made possible by the new speed of computation, though they are threatened by cybersecurity. Chemical and other engineers, technicians, operators and all those who work in the process industries will need to understand and work with these technologies as they mature.
These volumes arrive at the right time for the new generation, who will enable these technologies and develop new ones to strengthen the process industries and make the world a better place.
June C. WISPELWEY
Executive Director and CEO
AIChE
Introduction
This book, a result of knowledge exchange between the academic and industrial worlds, aims to introduce process industries to students, teachers, researchers, professionals, decision-makers, and, in general, the general public, at a time when they are affected by the digital revolution that accompanies the ongoing energy and environmental transitions.
These industries aim to transform and/or separate matter by chemical, physical or biological means. They cover huge and often complex fields such as chemistry, petroleum, pharmaceuticals, cosmetics, metallurgy, food industry, biotechnology, environmental and energy industries, among others. Their economic and societal importance is considerable.
These companies create value through their products from industrial facilities (workshops, factories) that implement specific technologies and processes. The science enabling this implementation is called “chemical engineering” (génie des procédés in French).
The French name is to be credited to the late Professor Jacques Villermaux of the École nationale supérieure des industries chimiques (ENSIC, the French National School of Chemical Industries) in Nancy, who noted that all the knowledge and techniques of chemical engineering could be perfectly applied, beyond the chemical and petroleum industries, to all process industries.
This book is an invitation to discover the operational modes and technical and industrial management of these industries. It attempts to succinctly answer the following questions:
Introduction written by Jean-Pierre Dal Pont and Marie Debacq.
– What is a company?
– What are its foundations and how is it organized?
– How does it respond to what is today known as CSR (corporate social responsibility)?
– How does it cooperate with its stakeholders (clients, stockholders, employees, administration, etc.) when the concept of capitalism with a human face is born which, in addition to remunerating its shareholders, wants to display its contribution to the common good?
– How does it design its commercial products based on the results of its research?
– How does it build and manage its plants and factories to manufacture and distribute its products, after having assessed their impact on the environment through an eco-design analysis based on LCA (Life cycle Assessment)?
– What are the scientific bases and the “technological elements” that the chemical engineer, at the heart of the process, will use to design and operate the
manufacturing facility
?
To ensure their sustainability, process companies must adapt to their socioeconomic environment, and, more particularly, to the society they shape through their innovations and products. In particular, they can help respond to the major challenges of today’s world, such as that of population growth: if we believe the forecasts, there will be two billion more people to feed by 2050. Growing urbanization will also create quickly insurmountable problems if they are not managed now: a city like Chongqing, on the banks of the Yangtze, has a population that represents half of the population of France. The concepts of Smart Cities and Smart Buildings are therefore essential. As for climate change, this is perhaps the biggest challenge on the planet: the water stress associated with it will affect at least 17 countries, including India. Water is life!
Added to this is the fact that the increasingly enlightened consumer wants to know what they have on their plate, to be informed about the origin of the products they use. Traceability, authentication, naturalness, fair trade, etc. are concepts that manufacturers can no longer ignore. For example, the world is worried about the future of plastics: The Great Pacific Garbage Patch and the North Atlantic Garbage Patch1, which are several times the size of France, are dumbfounding.
1 Continents of plastic floating on the oceans, sheltering an aquatic fauna that feeds on it and enters the food chain.
This book is particularly interested in the industrial facility at the center of the company. The future of it will depend heavily on its design and its technical and human implementation. Manufacturing operations are no longer considered dirty jobs; it is a given that wealth is built in the workshop (or on the shop floor). Thus, Toyotism, also called “lean manufacturing”, is there to prove it: this production system has enabled Toyota to create an empire in the automotive industry and surpass the Americans in their own country.
In recent years, the digital revolution has brought about a radical change (disruption) at the societal level and at the level of companies, both at the managerial and productive levels. It was made possible by the increased power of computers (Moore’s law), by the multiplication of sensors, their miniaturization, their low cost, and the development of algorithms. The notion of artificial intelligence (AI), which brings together a set of computer applications and algorithms based on the processing and exploitation of Big Data, testifies to this industrial revolution in progress. AI modifies our lives, our professions, our way of moving, very often, of taking care of ourselves, without our being aware of it. This term pervades books, articles, speeches and private and government research programs. Smartphones and tablets, which are only about 10 years old, are one of the essential pieces of media of this revolution. Who could do without it today?
In addition to AI, the digital revolution has brought with it a number of digital tools that underpin the concept of the factory of the future, born in Germany under the name “factory 4.0”. The factory of the future combines the virtual world with the real world. These tools include the IoT (Internet of Things) - everything is connected and everything is connectable - virtual reality, augmented reality, digital twins, additive manufacturing (3D printers), etc. The world of work is deeply affected by robotics and cobotics. We must expect an industry to emerge where repetitive, tiring, messy and even dangerous tasks will be eliminated. The operator will be more of a supervisor than a performer.
Added to this is the fact that the concept of sustainable development, the basis of CSR, is now mature, including the need for metrics. Industry is moving towards a circular, low-carbon and, no doubt, decentralized economy. Bio-industries are not immune to this development with the development of synthetic biology, a remarkable future technological tool, but subject to controversy from the ethical standpoint.
In this shifting context, it is therefore difficult to grasp what the evolution of employment will be; dignified roles are created (Data Officer), while subordinate tasks are on the way out.
Are we moving towards a civilization of algorithms? Their opacity raises fears of the advent of a “Black Box Society” where individual freedom is in danger. Everything is known, everything can be known! Our societies - already based on science, technology and knowledge - will become increasingly connected and undoubtedly more complex and more vulnerable.
GAFA (Google, Apple, Facebook, and Amazon), the most powerful digital Internet companies in the world, are already frightening with their capital power, supranationality, and speed of deployment. In this global technological race where everything is accelerating, China has now entered the fray and faces the United States.
These are the reflections that this work invites us to. This book hopes to be interactive and accessible for everyone; it refers to illustrative videos and presents concrete examples, offered by leading figures in the form of boxes. These are listed at the end of each volume.
Videos
The following link to a website makes it easy to access the resources that illustrate this work, in particular, the videos:
https://frama.link/livreIndustriesProcedes
The links and videos are classified by volume and by chapter (via the menu on the left) in the order of appearance in the book.
Volume 1: Sustainability, Managerial and Scientific Fundamentals
Chapter 1: Industries, Businesses and People (Jean-Pierre Dal Pont): this first chapter is devoted to the industry and the businesses that depend on it. It focuses on process industries, while highlighting what differentiates them from the manufacturing and service industries. The themes concerning their constitution, strategy, functioning and governance are discussed.
Chapter 2: Earth, Our Habitat: Products by the Millions, the Need for Awareness (Jean-Pierre Dal Pont and Michel Royer): dedicated to the relationship between products and the environment, this chapter initiates a reflection on our way of life. Earth, our habitat, is a finite space whose complex cycles depend on anthropic activities: we can cite, for example, atmospheric chemistry and the problem of ozone. The vital systems of water, food, energy and climate are referred to as a “nexus”, because they are interdependent. Products, whose quantity is increasing with the population explosion, must be ecodesigned using LCA (Lifecycle Assessment), toxicology, ecotoxicology and traceability studies, and turn to biobased raw materials. The circular economy must prevail over a linear economy, which consists of extracting, producing, consuming and throwing away.
Chapter 3: Designing Chemical Products (Willi Meier): Chapter 3 is dedicated to product design and formulation. A product must be designed to meet the needs of customers. In now saturated markets, companies are turning to often complex functionalized products. Post-its are a vivid example: at first, it was just a glue that stuck badly! Who could do without them today? Increasingly based on bio-sourced raw materials and biotechnologies, products use additives: ingredients such as starch and gelatin. This is the case for drugs that can also be encapsulated with alginates to reach the right target at the right time. The story of Aspirin®, first synthesized by Bayer in 1897, is remarkable. Its survival is due, in part, to sophisticated formulations. Another example of the development of drinkable formulations is coffee. The formulation of environment-friendly “smart” products in the field of textiles or fertilizers, for example, is a science with a bright future.
Chapter 4: Chemical Engineering: Introduction and Fundamentals (Marie Debacq, Alain Gaunand and Céline Houriez): chemical engineering, although omnipresent, is almost unknown to the general public. The beginning of this chapter therefore endeavors to give some definitions and historical benchmarks about this young applied science. The fundamentals of chemical engineering are then presented: starting with thermodynamics, then transfers, and finally chemical kinetics and catalysis. The last part of the chapter presents the “system-balancesperformance” approach for process design using two simple examples. A box presents the very first level of calculation on processes, namely material balances.
Chapter 5: Chemical Engineering: Unit Operations (Marie Debacq): the concept of a unit operation has made it possible to bring together, in large categories, the innumerable equipment used by the process industries. There are numerous unit operations and there is no a question of giving an exhaustive presentation here. This chapter therefore covers some of them, chosen because they are particularly symbolic or representative of one type of operation or another. Thus, the following are presented: distillation, the most important separation operation and also certainly the most scientifically mature; some fluid/solid mechanical separation operations, very widespread industrially but still relatively empirical today; agitation, as a symbol of the importance of hydrodynamics (that is to say, the study of fluid movements) in chemical engineering; heat exchangers, the main representatives of transfer operations (heat exchangers dealing with the process of heat transfer); and, finally, reactors, which are at the heart of processes and responsible for the transformation of matter on the scale of the molecules themselves.
Volume 2: Industrial Management and the Digital Revolution
Chapter 1: Bio-industry in the Age of the Transition to Digital Technology: Significance and Recent Advances (Philippe Jacques): the digital revolution is profoundly changing the profession of engineers involved in bio-industries. This chapter describes the main stages of development of a product of microbial origin and how approaches related to bioinformatics, synthetic biology, systems biology and microfluidics will make it possible to amplify the development of this growing economic sector.
Chapter 2: Hydrogen Production by Steam Reforming (Marie Basin, Diana Tudorache, Matthieu Flin, Raphaël Faure and Philippe Arpentinier): this chapter presents the most widely used hydrogen production process in the world: steam reforming of natural gas. All the technological elements of this process are described, as are the problems of industrial operation of these units. Current and future developments, including those aimed at minimizing carbon dioxide emissions, are also discussed.
Chapter 3: Industrialization: From Research to Final Product (Jean-Pierre Dal Pont): the process includes all the technologies that plants and factories use to manufacture a product or a set of products. Very generally, this is a reaction followed by purification: a drug or a product to protect plants, often complex molecules, are the result of several reactions and several separations or purifications called “unit operations”, described elsewhere.
The purpose of this chapter is to describe the industrialization process, which, starting from research, will define the production tool. At the end of the chapter, two boxes describe the increasingly sought-after modular construction and the constraints and advantages of a multi-workshop platform.
Chapter 4: Operations (Jean-Pierre Dal Pont): operations, or manufacturing, designate the implementation of industrial facilities (plants or factories). They are an essential function of the process industries, the source of their products and related services, and, therefore, of their profit.
This chapter studies production, its flows (financial, information, materials), and the increasingly sophisticated IT tools that make it possible to manage them such as ERP (Enterprise Resource Planning). It also discusses the bases for calculating the cost price of products and margins. Finally, special thought is given to change management: to last is also to change.
Chapter 5: The Enterprise and The Plant of the Future at the Age of the Transition to Digital Technology (Jean-Pierre Dal Pont): Chapter 5 recalls the industrial revolutions that have followed one another since the invention of the steam engine, a source of energy at the beginning of the 18th Century, to the present day. It analyzes their impact on society and on the capital-intensive business as we know it today. Emphasis is placed on information technology, which took off after the Second World War. The emergence of the Internet around 1990, that of the smartphone around 2000, and the beginnings of artificial intelligence initiated the digital revolution, whose unprecedented impact we are already seeing on society and industry. Many boxes give examples of the use of AI in fields as varied as autonomous cars, underwater exploration, robotics and industrial management.
Chapter 6: And Tomorrow... (Jean-Pierre Dal Pont): this last chapter is a reflection on the digital revolution as it is perceived today and, more particularly, on artificial intelligence, which is its standard-bearing media. AI is increasingly affecting the city which wants to be smart. The water sector is taken as an example of economic activity whose digital aspect modifies the processes, the management of the distribution networks and the trades.
