Seuraajasuunnitteluprosessi ja sen toimivuus KONE Oyj:n New Equipment Business -liiketoimintayksikössä

Tämä tutkimus käsittelee seuraajasuunnitteluprosessia ja sen toimivuutta. Tutkimus on tapaustutkimus, jossa tutkittava ilmiö eli seuraajasuunnittelu ja kohteena oleva tapaus eli organisaatio KONE Oyj:n yksi liiketoimintayksikkö New Equipment Business, NEB voidaan erottaa toisistaan. Tutkimuksen kohteena on seuraajasuunnitteluprosessin toimivuus tapausorganisaatiossa. Tutkimuksen tarkoituksena on hankkia tietoa ja ymmärtää prosessin toteutumista sekä löytää jo käytössä olevat parhaimmat käytännöt sekä merkittävimmät kehitysalueet. Tutkimuksen lähestymistapa on kvalitatiivinen. Seuraajasuunnitteluprosessin toimivuutta tutkittiin tekemällä teemahaastatteluja tutkimuksen kohteena olevan organisaation eri funktioiden henkilöstöpäälliköiden ja yksiköiden johtajien kanssa. Haastattelujen lisäksi tutkimuksessa käytettiin tausta-aineistona yrityksen sisäisiä arkistointitietoja ja materiaalia. Työn tuloksena saatiin selville, miten seuraajasuunnitteluprosessi toteutuu kohdeorganisaatiossa. Tutkimuksen tulosten perusteella näyttää siltä, että panostamalla talenttien kehitystoimenpiteisiin sekä lisäämällä henkilöiden liikkuvuutta yli organisaatiorajojen voidaan kehittää seuraajasuunnitteluprosessia vastaamaan tulevaisuuden haasteisiin.

Computational studies for the design of process equipment with complex geometries

This study combines several projects related to the flows in vessels with complex shapes representing different chemical apparata. Three major cases were studied. The first one is a two-phase plate reactor with a complex structure of intersecting micro channels engraved on one plate which is covered by another plain plate. The second case is a tubular microreactor, consisting of two subcases. The first subcase is a multi-channel two-component commercial micromixer (slit interdigital) used to mix two liquid reagents before they enter the reactor. The second subcase is a micro-tube, where the distribution of the heat generated by the reaction was studied. The third case is a conventionally packed column. However, flow, reactions or mass transfer were not modeled. Instead, the research focused on how to describe mathematically the realistic geometry of the column packing, which is rather random and can not be created using conventional computeraided design or engineering (CAD/CAE) methods. Several modeling approaches were used to describe the performance of the processes in the considered vessels. Computational fluid dynamics (CFD) was used to describe the details of the flow in the plate microreactor and micromixer. A space-averaged mass transfer model based on Fick’s law was used to describe the exchange of the species through the gas-liquid interface in the microreactor. This model utilized data, namely the values of the interfacial area, obtained by the corresponding CFD model. A common heat transfer model was used to find the heat distribution in the micro-tube. To generate the column packing, an additional multibody dynamic model was implemented. Auxiliary simulation was carried out to determine the position and orientation of every packing element in the column. This data was then exported into a CAD system to generate desirable geometry, which could further be used for CFD simulations. The results demonstrated that the CFD model of the microreactor could predict the flow pattern well enough and agreed with experiments. The mass transfer model allowed to estimate the mass transfer coefficient. Modeling for the second case showed that the flow in the micromixer and the heat transfer in the tube could be excluded from the larger model which describes the chemical kinetics in the reactor. Results of the third case demonstrated that the auxiliary simulation could successfully generate complex random packing not only for the column but also for other similar cases.

Utilization of steelmaking waste materials for production of calcium carbonate (CaCO3)

The steel industry produces, besides steel, also solid mineral by-products or slags, while it emits large quantities of carbon dioxide (CO2). Slags consist of various silicates and oxides which are formed in chemical reactions between the iron ore and the fluxing agents during the high temperature processing at the steel plant. Currently, these materials are recycled in the ironmaking processes, used as aggregates in construction, or landfilled as waste. The utilization rate of the steel slags can be increased by selectively extracting components from the mineral matrix. As an example, aqueous solutions of ammonium salts such as ammonium acetate, chloride and nitrate extract calcium quite selectively already at ambient temperature and pressure conditions. After the residual solids have been separated from the solution, calcium carbonate can be precipitated by feeding a CO2 flow through the solution. Precipitated calcium carbonate (PCC) is used in different applications as a filler material. Its largest consumer is the papermaking industry, which utilizes PCC because it enhances the optical properties of paper at a relatively low cost. Traditionally, PCC is manufactured from limestone, which is first calcined to calcium oxide, then slaked with water to calcium hydroxide and finally carbonated to PCC. This process emits large amounts of CO2, mainly because of the energy-intensive calcination step. This thesis presents research work on the scale-up of the above-mentioned ammonium salt based calcium extraction and carbonation method, named Slag2PCC. Extending the scope of the earlier studies, it is now shown that the parameters which mainly affect the calcium utilization efficiency are the solid-to-liquid ratio of steel slag and the ammonium salt solvent solution during extraction, the mean diameter of the slag particles, and the slag composition, especially the fractions of total calcium, silicon, vanadium and iron as well as the fraction of free calcium oxide. Regarding extraction kinetics, slag particle size, solid-to-liquid ratio and molar concentration of the solvent solution have the largest effect on the reaction rate. Solvent solution concentrations above 1 mol/L NH4Cl cause leaching of other elements besides calcium. Some of these such as iron and manganese result in solution coloring, which can be disadvantageous for the quality of the PCC product. Based on chemical composition analysis of the produced PCC samples, however, the product quality is mainly similar as in commercial products. Increasing the novelty of the work, other important parameters related to assessment of the PCC quality, such as particle size distribution and crystal morphology are studied as well. As in traditional PCC precipitation process, the ratio of calcium and carbonate ions controls the particle shape; a higher value for [Ca2+]/[CO32-] prefers precipitation of calcite polymorph, while vaterite forms when carbon species are present in excess. The third main polymorph, aragonite, is only formed at elevated temperatures, above 40-50 °C. In general, longer precipitation times cause transformation of vaterite to calcite or aragonite, but also result in particle agglomeration. The chemical equilibrium of ammonium and calcium ions and dissolved ammonia controlling the solution pH affects the particle sizes, too. Initial pH of 12-13 during the carbonation favors nonagglomerated particles with a diameter of 1 μm and smaller, while pH values of 9-10 generate more agglomerates of 10-20 μm. As a part of the research work, these findings are implemented in demonstrationscale experimental process setups. For the first time, the Slag2PCC technology is tested in scale of ~70 liters instead of laboratory scale only. Additionally, design of a setup of several hundreds of liters is discussed. For these purposes various process units such as inclined settlers and filters for solids separation, pumps and stirrers for material transfer and mixing as well as gas feeding equipment are dimensioned and developed. Overall emissions reduction of the current industrial processes and good product quality as the main targets, based on the performed partial life cycle assessment (LCA), it is most beneficial to utilize low concentration ammonium salt solutions for the Slag2PCC process. In this manner the post-treatment of the products does not require extensive use of washing and drying equipment, otherwise increasing the CO2 emissions of the process. The low solvent concentration Slag2PCC process causes negative CO2 emissions; thus, it can be seen as a carbon capture and utilization (CCU) method, which actually reduces the anthropogenic CO2 emissions compared to the alternative of not using the technology. Even if the amount of steel slag is too small for any substantial mitigation of global warming, the process can have both financial and environmental significance for individual steel manufacturers as a means to reduce the amounts of emitted CO2 and landfilled steel slag. Alternatively, it is possible to introduce the carbon dioxide directly into the mixture of steel slag and ammonium salt solution. The process would generate a 60-75% pure calcium carbonate mixture, the remaining 25-40% consisting of the residual steel slag. This calcium-rich material could be re-used in ironmaking as a fluxing agent instead of natural limestone. Even though this process option would require less process equipment compared to the Slag2PCC process, it still needs further studies regarding the practical usefulness of the products. Nevertheless, compared to several other CO2 emission reduction methods studied around the world, the within this thesis developed and studied processes have the advantage of existing markets for the produced materials, thus giving also a financial incentive for applying the technology in practice.

Promoting Cleantech in Emerging Markets: Business Model for Waste Pre-treatment Equipment in China

Waste incineration is becoming increasingly widespread method of waste disposal in China. Incineration plants mostly use grate and circular fluidized bed (CFB) technology. Waste combustion in cement production is also beginning to gradually increase. However, Chinese waste composition is causing problems for the energy utilization. Mechanical waste pre-treatment optimizes the combustion process and facilitates the energy recovery. The objective of this study is to identify how Western waste pre-treatment manufacturer could operate in Chinese markets. Chinese waste management industry is reviewed via PESTEL analysis. The current state and future predictions of grate and CFB incineration as well as cement manufacturing are monitored. Grate combustion, which requires lesser waste pre-treatment, is becoming more common at the expense of CFB incineration in China. The most promising future for waste treatment is in cement production industry. Waste treatment equipment manufacturer should try to create pilot projects with biggest cement producers with a view of growing co-operation in the future.

The demand-supply balancing process in supply chain management - case mining & metals industry equipment

The aim of this thesis is to search how to match the demand and supply effectively in industrial and project-oriented business environment. The demand-supply balancing process is searched through three different phases: the demand planning and forecasting, synchronization of demand and supply and measurement of the results. The thesis contains a single case study that has been implemented in a company called Outotec. In the case study the demand is planned and forecasted with qualitative (judgmental) forecasting method. The quantitative forecasting methods are searched further to support the demand forecast and long term planning. The sales and operations planning process is used in the synchronization of the demand and supply. The demand forecast is applied in the management of a supply chain of critical unit of elemental analyzer. Different meters on operational and strategic level are proposed for the measurement of performance.

Study on Customer Perceived Value of Container Loading Equipment

The goal of the thesis was to gain understanding of organizational buying behavior and its effect from the selling perspective and to generate base for verifying customer value propositions for Actiw Oy. The first objective was to discover the current buying decision criteria of current customers to understand the buying motives which had led to the investment initially. Second objective was to understand how the buying decision criteria and customer experiences can be turned into customer value propositions. Research was done with 16 customer interviews, which were focused on obtaining the information on the buying center and the value of the solution. Thesis goes through the main theories of OBB and the theory behind customer value management. Based on customer interviews, the currently used customer value propositions were tested and categorized into points-of-parities and points-ofdifferences. The interviews confirmed customer behavior in new task and modified rebuy situations and also gave confirmation to the internally done customer value propositions. Main finding of the study was, that as the value propositions are possible to present more specifically to each new case instead of using all benefits at the same time.

Prosessiteollisuuden sekoittimen elinkaariarviointi

Työn tavoitteena oli tehdä elinkaariarviointi (LCA) prosessiteollisuuden sekoittimelle Helmix HF-80 ja analysoida LCA-tulokset, vaikutus ilmaston lämpenemisen potentiaalin (GWP) suhteen, sekä tutkia GWP-vaikutuksen pienentämisen mahdollisuuksia. Tutkittavan sekoittimen mahdolliset käyttökohteet ovat sellu- ja paperiteollisuus, raskaiden jätenesteiden käsittely, sekä muut teollisuusalueet, joissa käytetään tämän tyyppisiä laitteita. Työssä on muun muassa käsitelty sekoitusprosessit, sekoituslaitteiden tyypit, niiden rakenteiden ominaisuudet, käyttötarkoitus, toimintaperiaatteet, sekä sellu- ja paperi-teollisuudessa käytettävien sekoittimien yleiskatsaus. Työssä on myös kuvattu elinkaariarviointi (LCA) -menetelmä ja sen käyttötarkoitus. Tärkeimmistä tuloksista voi mainita sen, että sekoittimen (ilman säiliötä, sähkömoottoria ja vaihteistoa) kokoelinkaaren ilmastonlämpenemisen potentiaali (GWP) on noin 750 000 kg CO2-Equiv. Sekoittimen tuotanto- ja kierrätysaikana syntyy vain 1200 kg CO2-Equiv. ja suurin osa 748 000 kg CO2-Equiv. johtuu sähköenergian kulutuksesta käytön aikana. Käyttöajan vaikutusta voisi pienentää arvoksi 0 kg CO2-Equiv. käyttämällä pelkästään uusiutuvaa energiaa. Jos tuotantoaikana käytetty energia myös korvataan uusiutuvalla energialla, niin GWP-arvo koko elinkaaren aikana laskee arvoon 1006 kg CO2eqv., mikä on vain 0,13 % saaduista tuloksista. Suurin osa tästä arvosta liittyy sekoittimen materiaalin, tässä tapauksessa ruostumattoman teräksen tuotantoon.

Factors Affecting Runnability of Press Forming Equipment

The growth of the food packaging industry has raised more interest in bio-based fibre packing. The use of petroleum based packages is unfriendly to the environment while bio-based is a sustainable option for food packing. In this Master Thesis the aim was to discover how the press forming machineries runnability is affected by parameters of the press and how it also affects formability of paperboard trays. Familiarisation of the working operation parameters was done with the KAMA ST 75 flat-bed die cutting machine and the VP3-70 mould press. Some small test runs of moulding trays where done to get acquainted to the adjustment parameters of the machines. Literature study was done on how paperboards physical properties react to the forces applied during press forming. The study of what kind of defects to the paperboard tray might occur during forming process and the causes for these defects. Also how the parameters of the press forming machine affects formability of the tray. Maintenance procedures was done to the press forming machine to enhance the reliably of production process. Tool alignment measurement was done to determine proper alignment. Laboratory test of the physical properties of the test material was done to find any connection to how the test material performs in press forming. An evaluation criterion was made to evaluate the dimensions and defects of the tray. From the test result a conclusion can be drawn on how the parameters of the press forming process affect the paperboard material. Based on the results the adjustment the parameters of moulding machines to the mechanical properties of paperboard it is possible to produce high quality fibre passed trays for the food packaging industry.

Standardized electrical tests for electrical equipment in road vehicles Case: Visedo Oy PowerMASTER M-frame

Electrical road vehicles were common at the begin of the 20th century but internal combustion engines took a victory from electrical motors in road vehicles. The acknowledgement of the environment, and the price and the availability of the crude oil are reasons for the comeback of the electrical vehicles. Advancement in industrial technology and political atmosphere in EU as the directive 20--20--20, which consists of reducing fossil emission, increasing renewable energy and increasing the energy efficiency, have made the electrification popular again. In this thesis tests based on standard ISO 16750--2 electrical loads for electrical equipment in road vehicles are made for Visedo Oy's PowerMASTER M-frame power electronics device. This device is designed for mainly drive trains in mobile work machines and marine vessels but can be used in other application in its power range which also includes road vehicles. The functionality of the device is tested with preliminary tests which act as a framework for the tests based on standards.