figure 3.1.: photo of the circored plant. ~ 160 m iron ore fines cfb preheater inclined bucket...
TRANSCRIPT
Figure 3.1.: Photo of the Circored Plant
~ 160 m
Iron OreFines
CFBPreheater
InclinedBucket
Elevator
1st StageCFB Reactor
2nd StageFB Reactor
BriquettingPlant
HBI Product
ProcessGasHeatExchanger Process Gas
Compressor
Fired Gas Heaters
~ 1
10
m
ElectricalSubstation&ControlRoom
Figure 3.2.: Engineering drawing
Inventory / Buffers• Do NOT have a capacity; however, there might be a limited number of flow units that can be put in this inventory space at any moment of time• Multiple flow unit types possible
Arrows• Indicate the flow of the flow unit• Multiple flow unit types possible (see Section 3.5)
Activities• Carried out by resources• Add value and are required for completion of the flow unit• May or may not carry inventory• Have a capacity (maximum number of flow units that can flow through the activity within a unit of time)
Figure 3.3: Elements of a Process
Pre-Heater
Pile of Iron ore fines
Figure 3.4.: Process flow diagram, first step
Lock Hoppers
1st Reactor 2nd Reactor
Figure 3.5: Process Flow diagram (to be continued)
Pre-Heater
Pile of Iron ore fines
Figure 3.6. : Completed process flow diagram for the Circored process
Flash HeaterDischargeBriquetting
Lock Hoppers
1st Reactor 2nd ReactorPre-Heater
Pile of Iron ore fines
Finished Goods
Figure 3.7. : Completed process flow diagram for the Circored process
Pile of Iron ore fines
Pre-Heater
Briquet- tingFlash
heater
Dis-charge
Finishedgoods
Lock Hoppers
1st Reactor
2nd Reactor
Demand
InputBottleneck(Capacity)
Excess capacity
Flow RateDemand
InputBottleneck(Capacity)
Excess capacity
Flow Rate
Supply constrained Demand constrained
Demand
InputBottleneck(Capacity)
Excess capacity
Flow RateDemand
InputBottleneck(Capacity)
Excess capacity
Flow Rate
Supply constrained Demand constrained
Figure 3.8.: Supply constrained (left) and demand constrained (right) process
Preheater LockHoppers
CFB StationaryReactor
Flashheater
Pressurelet-downsystem
Briquettingmachine
Totalprocess
Imbalance relativeTo bottleneck
Mismatch between demand andsupply at the process level
Bottleneck
Preheater LockHoppers
CFB StationaryReactor
Flashheater
Pressurelet-downsystem
Briquettingmachine
Totalprocess
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Imbalance relativeTo bottleneck
Mismatch between demand andsupply at the process level
Bottleneck
Figure 3.9.: Utilization Profile
Utilization
Flash HeaterDischargeBriquetting
Lock Hoppers
1st Reactor 2nd ReactorPre-Heater
Pile of Iron ore fines
Finished Goods
7.5% Outflow 15% Outflow 10% Outflow
Flash HeaterDischargeBriquetting
Lock Hoppers
1st Reactor 2nd ReactorPre-Heater
Pile of Iron ore fines
Finished Goods
7.5% Outflow7.5% Outflow 15% Outflow15% Outflow 10% Outflow10% Outflow
Figure 3.10: Refined process flow diagram accounting for mass reduction
Internship
Staff
Consulting
FileVerified Applications
Contact faculty/other persons
Contact prioremployers
Benchmarkgrades
Confirmationletter
Internship
Staff
Consulting
FileVerified Applications
Contact faculty/other persons
Contact prioremployers
Benchmarkgrades
Confirmationletter
Figure 3.10: Process flow diagram with multiple product types
Compute theCapacity foreach of theResources
Use demand tocompute theimplied utilizationlevels
Identify theBottleneck
Prepare a Process FlowDiagram
Compute variousPerformancemeasures
Use differentColors to markFlow units
Note that capacity levels may differ depending on product type
Compute the work-load across all product types
Step with highest implied utilization
Extensions required for working with multiple flow units
Extensions required for working with multiple flow units
Compute theCapacity foreach of theResources
Use demand tocompute theimplied utilizationlevels
Identify theBottleneck
Prepare a Process FlowDiagram
Compute variousPerformancemeasures
Compute theCapacity foreach of theResources
Use demand tocompute theimplied utilizationlevels
Identify theBottleneck
Prepare a Process FlowDiagram
Compute variousPerformancemeasures
Use differentColors to markFlow units
Note that capacity levels may differ depending on product type
Compute the work-load across all product types
Step with highest implied utilization
Figure 3.11: Summary of process analysis