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Process engineering: An Example

The following example illustrates an application of process engineering principles in a task many process engineers face, that is how to increase the share of renewable energy sources (biomass in this case) in total heat consumption.

This particular task concerns a design and instalment of a modern medium-capacity biomass boiler within a small-scale commercial and municipal power industry with an installed capacity of units of MW.

Tasks of an engineer working “from scratch to launch”

In general
Regarding our example

Assessment of current situation and market survey

Options for utilization of energy plants Utilization of various types of biomass
Needs of potential clients Gap in the market concerning energy plants with the capacity of 1–3 MW

Research and development based on practice’s re­quirements

New process / innovation Prototype of a unit for energy production from biomass

Planning phase / Basic design

Design of the process conceptualization Determination of the energy plant’s capacity and capacity of gas boilers for back ups during energy peaks
Composition of the process using particular segments Preliminary footprint arrangement of the boiler room
Optimization of the apparatuses’ arrangements Connection of particular apparatuses for minimization of costs
Process engineer–manager makes decisions about the execution of the project.

Project implementation

Technical details For example, design of flue gas duct and pipe routes for supply of combustion air
Design of structure of apparatuses and equipment For example, calculations and documentation for hot-water exchanger
Drafting of the documentation
Sub-contractors Fans, pumps, measuring and control

Execution

Checking up on building and assembly work Erection of objects for the energy plant, area for location of the combustion chamber and other apparatuses, support constructions and stages
Individual and complex tests Tests of functionality of the fans, pumps, measuring devices, etc.
Performance guarantee test Validation of capacity and compliance with emission limits

Operations

Monitoring, acquisition and evaluation of operating data Evaluation of boiler efficiency
Troubleshooting Cleaning of heat-exchanging surface of the hot-water exchanger
Maintenance during temporary shut-downs
Research, development, feedback, modeling, simulation, 3D computational modeling ⇒ constant product’s inno­vations
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