Competition from emerging and developing countries, challenges related to energy and water, the continuing increase in the global population and the obligation to be sustainable are all impacting developed countries such as the United States, France, etc. Manufacturing has been almost totally neglected by these developed countries and thus there is a strong need to review R&D and the development and industrialization processes. This is a prerequisite for maintaining and improving welfare and quality of life. The industrialization process can be defined as the process of converting research or laboratory experiments into a physical tool capable of producing a product of value for customers of specified markets. Such a process implies knowledge of BAT (best available techniques) in chemical engineering, plant design, production competitiveness, the proper utilization of tools (toolbox concept) such as value assessment, value engineering, eco-design, LCA (lifecycle analysis), process simulation, modeling, innovation and appropriate metrics usage. These are mandatory to ensure commercial success and covered by the authors of this book.
A copper scrap management model at a country level is proposed, taking into account every collected copper scrap stream, with its associated environmental impact and cost. The method is applied on the treatment of printed wiring boards (PWB) in France. Considering the initial physical properties and composition of this scrap, seven flowsheets are constructed to produce refined copper. Then, depending on the ratio of PWB treated in each processing chain, the production rate, energy consumption, operating cost and environmental impact are evaluated. Three bi-objective optimizations are conducted based on a multi-objective genetic algorithm of NSGA II version: production versus energy consumption, production versus operating cost and production versus environmental impact. Pareto fronts are obtained for each optimization that gives the set of non-dominated solutions.
The well-known benchmark process for hydrodealkylation of toluene (HDA) to produce benzene is revisited in a multi-objective approach to identify environmentally friendly and cost-effective solutions. Some guidelines to develop an eco-design framework for chemical processes, involving multiple criteria to be satisfied simultaneously are proposed, based on simulation, optimization, multiple choice decision making procedures and life cycle assessment. Two studies related to the selection of the primary energy source, either fuel oil or natural gas for the utility production system (UPS) of the HDA process are conducted. In each case, a multi-objective optimization problem involving the total annual cost of the process, and five environmental burdens is carried out.
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