Facing the climate change challenges in the mining and mineral industry as providers of a sustainable manufacturing process

A sustainable manufacturing process must rely on an also sustainable raw materials and energy supply. This paper is intended to show the results of the studies developed on sustainable business models for the minerals industry as a fundamental previous part of a sustainable manufacturing process. As it has happened in other economic activities, the mining and minerals industry has come under tremendous pressure to improve its social, developmental, and environmental performance. Mining, refining, and the use and disposal of minerals have in some instances led to significant local environmental and social damage. Nowadays, like in other parts of the corporate world, companies are more routinely expected to perform to ever higher standards of behavior, going well beyond achieving the best rate of return for shareholders. They are also increasingly being asked to be more transparent and subject to third-party audit or review, especially in environmental aspects. In terms of environment, there are three inter-related areas where innovation and new business models can make the biggest difference: carbon, water and biodiversity. The focus in these three areas is for two reasons. First, the industrial and energetic minerals industry has significant footprints in each of these areas. Second, these three areas are where the potential environmental impacts go beyond local stakeholders and communities, and can even have global impacts, like in the case of carbon. So prioritizing efforts in these areas will ultimately be a strategic differentiator as the industry businesses continues to grow. Over the next forty years, world?s population is predicted to rise from 6.300 million to 9.500 million people. This will mean a huge demand of natural resources. Indeed, consumption rates are such that current demand for raw materials will probably soon exceed the planet?s capacity. As awareness of the actual situation grows, the public is demanding goods and services that are even more environmentally sustainable. This means that massive efforts are required to reduce the amount of materials we use, including freshwater, minerals and oil, biodiversity, and marine resources. It?s clear that business as usual is no longer possible. Today, companies face not only the economic fallout of the financial crisis; they face the substantial challenge of transitioning to a low-carbon economy that is constrained by dwindling natural resources easily accessible. Innovative business models offer pioneering companies an early start toward the future. They can signal to consumers how to make sustainable choices and provide reward for both the consumer and the shareholder. Climate change and carbon remain major risk discontinuities that we need to better understand and deal with. In the absence of a global carbon solution, the principal objective of any individual country should be to reduce its global carbon emissions by encouraging conservation. The mineral industry internal response is to continue to focus on reducing the energy intensity of our existing operations through energy efficiency and the progressive introduction of new technology. Planning of the new projects must ensure that their energy footprint is minimal from the start. These actions will increase the long term resilience of the business to uncertain energy and carbon markets. This focus, combined with a strong demand for skills in this strategic area for the future requires an appropriate change in initial and continuing training of engineers and technicians and their awareness of the issue of eco-design. It will also need the development of measurement tools for consistent comparisons between companies and the assessments integration of the carbon footprint of mining equipments and services in a comprehensive impact study on the sustainable development of the Economy.

On track for solar grade silicon through a siemens process-type laboratory reactor: operating conditions and energy savings

Polysilicon cost impacts significantly on the photovoltaics (PV) cost and on the energy payback time. Nowadays, the besetting production process is the so called Siemens process, polysilicon deposition by chemical vapor deposition (CVD) from Trichlorosilane. Polysilicon purification level for PV is to a certain extent less demanding that for microelectronics. At the Instituto de Energía Solar (IES) research on this subject is performed through a Siemens process-type laboratory reactor. Through the laboratory CVD prototype at the IES laboratories, valuable information about the phenomena involved in the polysilicon deposition process and the operating conditions is obtained. Polysilicon deposition by CVD is a complex process due to the big number of parameters involved. A study on the influence of temperature and inlet gas mixture composition on the polysilicon deposition growth rate, based on experimental experience, is shown. Moreover, CVD process accounts for the largest contribution to the energy consumption of the polysilicon production. In addition, radiation phenomenon is the major responsible for low energetic efficiency of the whole process. This work presents a model of radiation heat loss, and the theoretical calculations are confirmed experimentally through a prototype reactor at our disposal, yielding a valuable know-how for energy consumption reduction at industrial Siemens reactors.

Tool wear monitoring using neuro-fuzzy techniques: a comparative study in a turning process

Tool wear detection is a key issue for tool condition monitoring. The maximization of useful tool life is frequently related with the optimization of machining processes. This paper presents two model-based approaches for tool wear monitoring on the basis of neuro-fuzzy techniques. The use of a neuro-fuzzy hybridization to design a tool wear monitoring system is aiming at exploiting the synergy of neural networks and fuzzy logic, by combining human reasoning with learning and connectionist structure. The turning process that is a well-known machining process is selected for this case study. A four-input (i.e., time, cutting forces, vibrations and acoustic emissions signals) single-output (tool wear rate) model is designed and implemented on the basis of three neuro-fuzzy approaches (inductive, transductive and evolving neuro-fuzzy systems). The tool wear model is then used for monitoring the turning process. The comparative study demonstrates that the transductive neuro-fuzzy model provides better error-based performance indices for detecting tool wear than the inductive neuro-fuzzy model and than the evolving neuro-fuzzy model.

Transductive neurofuzzy-based torque control of a milling process: results of a case study

This paper presents the design and implementation of an intelligent control system based on local neurofuzzy models of the milling process relayed through an Ehternet-based application. Its purpose is to control the spindle torque of a milling process by using an internal model control paradigm to modify the feed rate in real time. The stabilization of cutting cutting torque is especially necessary in milling processes such as high-spedd roughing of steel moulds and dies tha present minor geometric uncertainties. Thus, maintenance of the curring torque increaes the material removal rate and reduces the risk of damage due to excessive spindle vibration, a very sensitive and expensive component in all high-speed milling machines. Torque control is therefore an interesting challenge from an industrial point of view.

About the origin of low wafer performance and crystal defect generation on seed-cast growth of industrial mono-like silicon ingots

The era of the seed-cast grown monocrystalline-based silicon ingots is coming. Mono-like, pseudomono or quasimono wafers are product labels that can be nowadays found in the market, as a critical innovation for the photovoltaic industry. They integrate some of the most favorable features of the conventional silicon substrates for solar cells, so far, such as the high solar cell efficiency offered by the monocrystalline Czochralski-Si (Cz-Si) wafers and the lower cost, high productivity and full square-shape that characterize the well-known multicrystalline casting growth method. Nevertheless, this innovative crystal growth approach still faces a number of mass scale problems that need to be resolved, in order to gain a deep, 100% reliable and worldwide market: (i) extended defects formation during the growth process; (ii) optimization of the seed recycling; and (iii) parts of the ingots giving low solar cells performance, which directly affect the production costs and yield of this approach. Therefore, this paper presents a series of casting crystal growth experiments and characterization studies from ingots, wafers and cells manufactured in an industrial approach, showing the main sources of crystal defect formation, impurity enrichment and potential consequences at solar cell level. The previously mentioned technological drawbacks are directly addressed, proposing industrial actions to pave the way of this new wafer technology to high efficiency solar cells.

Proposal for the Conceptual Design of Aeronautical Final Assembly Lines Based on the Industrial Digital Mock-Up Concept

The design of a Final Assembly Line (FAL) is carry out in the product industrialization activity. The phase dealing with the definition of conceptual solutions is characterized by depending heavily on the personnel experience and being time-consuming. To enhance such process, it is proposed a development of a knowledge based software application to assist designers in the definition of scenarios and to generate conceptual FAL alternatives. Both the scenario and the generated FAL solution are part of the industrialization digital mock-up (IDMU). A commercial software application used in the aircraft programmes and supporting the IDMU concepts of: Product, Process and Resource; was selected to implement a software prototype. This communication presents the adopted methodological approach and the architecture of the developed application.

Understanding and improving the chemical vapor deposition process for solar grade silicon production

Esta Tesis Doctoral se centra en la investigación del proceso de producción de polisilicio para aplicaciones fotovoltaicas (FV) por la vía química; mediante procesos de depósito en fase vapor (CVD). El polisilicio para la industria FV recibe el nombre de silicio de grado solar (SoG Si). Por un lado, el proceso que domina hoy en día la producción de SoG Si está basado en la síntesis, destilación y descomposición de triclorosilano (TCS) en un reactor CVD -denominado reactor Siemens-. El material obtenido mediante este proceso es de muy alta pureza, pero a costa de un elevado consumo energético. Así, para alcanzar los dos principales objetivos de la industria FV basada en silicio, bajos costes de producción y bajo tiempo de retorno de la energía invertida en su fabricación, es esencial disminuir el consumo energético de los reactores Siemens. Por otro lado, una alternativa al proceso Siemens considera la descomposición de monosilano (MS) en un reactor de lecho fluidizado (FBR). Este proceso alternativo tiene un consumo energético mucho menor que el de un reactor Siemens, si bien la calidad del material resultante es también menor; pero ésta puede ser suficiente para la industria FV. A día de hoy los FBR deben aún abordar una serie de retos para que su menor consumo energético sea una ventaja suficiente comparada con otras desventajas de estos reactores. En resumen, la investigación desarrollada se centra en el proceso de depósito de polysilicio por CVD a partir de TCS -reactor Siemens-; pero también se investiga el proceso de producción de SoG Si en los FBR exponiendo las fortalezas y debilidades de esta alternativa. Para poder profundizar en el conocimiento del proceso CVD para la producción de polisilicio es clave el conocimiento de las reacciones químicas fundamentales y cómo éstas influencian la calidad del producto resultante, al mismo tiempo que comprender los fenómenos responsables del consumo energético. Por medio de un reactor Siemens de laboratorio en el que se llevan a cabo un elevado número de experimentos de depósito de polisilicio de forma satisfactoria se adquiere el conocimiento previamente descrito. Se pone de manifiesto la complejidad de los reactores CVD y de los problemas asociados a la pérdidas de calor de estos procesos. Se identifican las contribuciones a las pérdidas de calor de los reactores CVD, éstas pérdidas de calor son debidas principalmente a los fenómenos de radiación y, conducción y convección vía gases. En el caso de los reactores Siemens el fenómeno que contribuye en mayor medida al alto consumo energético son las pérdidas de calor por radiación, mientras que en los FBRs tanto la radiación como el calor transferido por transporte másico contribuyen de forma importante. Se desarrolla un modelo teórico integral para el cálculo de las pérdidas de calor en reactores Siemens. Este modelo está formado a su vez por un modelo para la evaluación de las pérdidas de calor por radiación y modelos para la evaluación de las pérdidas de calor por conducción y convección vía gases. Se ponen de manifiesto una serie de limitaciones del modelo de pérdidas de calor por radiación, y se desarrollan una serie de modificaciones que mejoran el modelo previo. El modelo integral se valida por medio un reactor Siemens de laboratorio, y una vez validado se presenta su extrapolación a la escala industrial. El proceso de conversión de TCS y MS a polisilicio se investiga mediante modelos de fluidodinámica computacional (CFD). Se desarrollan modelados CFD para un reactor Siemens de laboratorio y para un prototipo FBR. Los resultados obtenidos mediante simulación son comparados, en ambos casos, con resultados experimentales. Los modelos desarrollados se convierten en herramientas para la identificación de aquellos parámetros que tienen mayor influencia en los procesos CVD. En el caso del reactor Siemens, ambos modelos -el modelo integral y el modelado CFD permiten el estudio de los parámetros que afectan en mayor medida al elevado consumo energético, y mediante su análisis se sugieren modificaciones para este tipo de reactores que se traducirían en un menor número de kilovatios-hora consumidos por kilogramo de silicio producido. Para el caso del FBR, el modelado CFD permite analizar el efecto de una serie de parámetros sobre la distribución de temperaturas en el lecho fluidizado; y dicha distribución de temperaturas está directamente relacionada con los principales retos de este tipo de reactores. Por último, existen nuevos conceptos de depósito de polisilicio; éstos se aprovechan de la ventaja teórica de un mayor volumen depositado por unidad de tiempo -cuando una mayor superficie de depósito está disponible- con el objetivo de reducir la energía consumida por los reactores Siemens. Estos conceptos se exploran mediante cálculos teóricos y pruebas en el reactor Siemens de laboratorio. ABSTRACT This Doctoral Thesis comprises research on polysilicon production for photovoltaic (PV) applications through the chemical route: chemical vapor deposition (CVD) process. PV polysilicon is named solar grade silicon (SoG Si). On the one hand, the besetting CVD process for SoG Si production is based on the synthesis, distillation, and decomposition of thriclorosilane (TCS) in the so called Siemens reactor; high purity silicon is obtained at the expense of high energy consumption. Thus, lowering the energy consumption of the Siemens process is essential to achieve the two wider objectives for silicon-based PV technology: low production cost and low energy payback time. On the other hand, a valuable variation of this process considers the use of monosilane (MS) in a fluidized bed reactor (FBR); lower output material quality is obtained but it may fulfil the requirements for the PV industry. FBRs demand lower energy consumption than Siemens reactors but further research is necessary to address the actual challenges of these reactors. In short, this work is centered in polysilicon CVD process from TCS -Siemens reactor-; but it also offers insights on the strengths and weaknesses of the FBR for SoG Si production. In order to aid further development in polysilicon CVD is key the understanding of the fundamental reactions and how they influence the product quality, at the same time as to comprehend the phenomena responsible for the energy consumption. Experiments conducted in a laboratory Siemens reactor prove the satisfactory operation of the prototype reactor, and allow to acquire the knowledge that has been described. Complexity of the CVD reactors is stated and the heat loss problem associated with polysilicon CVD is addressed. All contributions to the energy consumption of Siemens reactors and FBRs are put forward; these phenomena are radiation and, conduction and convection via gases heat loss. In a Siemens reactor the major contributor to the energy consumption is radiation heat loss; in case of FBRs radiation and heat transfer due to mass transport are both important contributors. Theoretical models for radiation, conduction and convection heat loss in a Siemens reactor are developed; shaping a comprehensive theoretical model for heat loss in Siemens reactors. Limitations of the radiation heat loss model are put forward, and a novel contribution to the existing model is developed. The comprehensive model for heat loss is validated through a laboratory Siemens reactor, and results are scaled to industrial reactors. The process of conversion of TCS and MS gases to solid polysilicon is investigated by means of computational fluid-dynamics models. CFD models for a laboratory Siemens reactor and a FBR prototype are developed. Simulated results for both CVD prototypes are compared with experimental data. The developed models are used as a tool to investigate the parameters that more strongly influence both processes. For the Siemens reactors, both, the comprehensive theoretical model and the CFD model allow to identify the parameters responsible for the great power consumption, and thus, suggest some modifications that could decrease the ratio kilowatts-hour per kilogram of silicon produced. For the FBR, the CFD model allows to explore the effect of a number of parameters on the thermal distribution of the fluidized bed; that is the main actual challenge of these type of reactors. Finally, there exist new deposition surface concepts that take advantage of higher volume deposited per time unit -when higher deposition area is available- trying to reduce the high energy consumption of the Siemens reactors. These novel concepts are explored by means of theoretical calculations and tests in the laboratory Siemens prototype.

Arquitectura industrial tabacalera en la España peninsular: secaderos y fábricas

La Arquitectura industrial del tabaco en España está representada por dos tipos de construcciones, que corresponden a las dos fases en las que se divide el proceso de producción del tabaco: los secaderos (arquitectura bioclimática donde se realiza el secado), y las fábricas (centros donde se elabora el tabaco procedente de los secaderos). Las fábricas se repartieron por todo el territorio español, ocupando preferiblemente los lugares costeros, aunque existen casos en los que su localización obedecía a razones políticas. Estos edificios, en su mayoría, incluidos en los centros históricos de las ciudades, han cambiando de uso, y las antiguas fábricas de tabaco se han transformado en su mayoría, en centros de cultura, o centros sociales y representativos. La tesis surge del análisis de las características constructivas de la arquitectura industrial del tabaco: de los secaderos y de las fábricas, por tratarse de una tipología con suficiente entidad y un ejemplo de arquitectura bioclimática de producción en el caso de los secaderos, y por conseguir haberse adaptado a otros usos en el caso de las fábricas. La arquitectura de producción emplea un lenguaje acorde con los avances de la industrialización, anticipando materiales y estructuras, y condensando en una tipología específica las complejas relaciones establecidas entre producto, hombres y espacio. Estos edificios tuvieron una extensa implantación en el territorio, y se caracterizan por una serie de valores tecnológicos, arquitectónicos, sociológicos y paisajísticos, que hacen de ellos un documento de primera magnitud para conocer: la evolución e implantación de las técnicas constructivas (materiales y estructuras), los procesos de innovación tipológica y la estructura económica y procedimientos técnicos utilizados. El territorio en el que se insertan constituye su contexto territorial, por lo que no sería adecuado considerar estos edificios como elementos aislados, sin analizar la relación con el entorno en el que se generaron. Por este motivo, se analizan las condiciones higrotérmicas ambientales de los secaderos para compararlas con las de confort humano y establecer relaciones y parámetros compatibles. Los ejemplos analizados de secaderos son todos de fábrica. El uso del ladrillo como módulo principal para la elaboración de un edificio, supone la consideración de un “grado cero” de todo el aparato constructivo y compositivo de la arquitectura. Dejar el ladrillo visto, supone hacer explícitos todos los procesos acumulativos. Este elemento mínimo, permite unas posibilidades enormemente abiertas, pero no absolutamente aleatorias, que definen su propia lógica combinatoria. La exigencia de sinceridad, característica de la arquitectura industrial, en la exposición de los materiales, exhibiéndolos en su propia naturaleza y en el modo real de ser utilizados, se hace patente en este tipo de construcción. Se realiza un estudio de permeabilidad en las fachadas de los secaderos, para determinar el grado de ventilación y su relación con la orientación, el patrón de celosía empleado y el volumen total. Este sistema de acondicionamiento climático específico, puede servir de recurso a otras construcciones, por lo que se podría trasladar el sistema constructivo y formal de los secaderos a otros usos, desde una doble vertiente: Arquitectura para la adaptación climática al entorno. Arquitectura como generadora de condiciones climáticas específicas, en el interior. La utilidad de los secaderos es fundamentalmente: proporcionar sombra, ventilación y un espacio cubierto, pero permeable en sus fachadas. La arquitectura industrial debe ser reconocida dentro del conjunto patrimonial, debido a sus características propias que permiten su diferenciación del resto de la arquitectura. Conocer la estructura productiva permite analizar correctamente estas construcciones, ya que el programa inicial es básico para entender la organización del espacio interior. Las fábricas no se situaron cerca de las zonas de producción del tabaco, excepto en dos casos: Cádiz y Palazuelo, en los que existen secaderos y campos de cultivo de hoja de tabaco en las áreas cercanas. La principal causa de esta separación es que el proceso de obtención de tabaco es un proceso dividido en dos fases principales: proceso primario y proceso secundario. En el proceso primario la hoja de tabaco se seca en los secaderos, en los que es determinante el clima, pero únicamente en el caso del secado del tabaco al aire. En el proceso secundario sin embargo, el tabaco llega previamente tratado a las fábricas, por lo que no influye el clima en esta parte del proceso. Esta razón determina que en las áreas climáticas donde se centra el estudio, haya zonas en las que existen fábrica y secaderos y otras en las que únicamente existe fábrica, o sólo secaderos. La localización de las fábricas atendía a razones de muy diferente índole, las más importantes fueron: geográficas, estratégicas, y políticas. En la mayoría de las fábricas la elección de la ciudad de emplazamiento estaba ligada a la recepción de la materia prima, que principalmente se hacía por vía marítima, o acuática (el caso de Sevilla), y por vía terrestre, utilizando como medio de transporte el ferrocarril. Sólo dos casos, de las antiguas fábricas, corresponden a razones políticas, son las dos únicas que no están en la costa: Madrid y Logroño. La de Madrid se construyó por centralidad política, y porque geográficamente ocupaba el punto central de todas las comunicaciones terrestres por carretera y ferrocarril. Muchas de las fábricas se situaron cercanas a las estaciones de ferrocarril. La de Logroño atendió, sin embargo, a razones políticas. Para finalizar, se realiza un estudio comparativo de las fábricas de Sevilla, Madrid y San Sebastián. Las razones que justifican esta elección son: - La de Sevilla fue históricamente la primera fábrica y la más importante. - La de Madrid fue la más importante a nivel administrativo, la sede de Tabacalera se instaló en la capital, y después de la de Sevilla, fue la que sirvió de modelo al resto de las fábricas. - La de San Sebastián era la más grande del Norte. Los análisis que se han realizado son de: volumen y superficies de patios, superficies de cubierta, permeabilidad o huecos en fachadas, orientación y soleamiento de patios, distribución espacial interior y organización, y evolución de usos. Podemos observar que en la mayoría de estas fábricas ha habido una transformación en el uso, pasando de ser edificios industriales a edificios culturales. Estas construcciones se pueden considerar como infraestructuras adaptables, por ser útiles, sostenibles y funcionales. ABSTRACT The Spanish industrial architecture of tobacco is represented by two construction types that correspond to the two phases of tobacco production: the drying sheds (bioclimatic constructions where the drying process takes place) and factories (centres where tobacco is processed after the drying process). The factories were distributed throughout the Spanish territory, preferably occupying coastal locations, although some of them were located elsewhere following political reasons. Most of the buildings inside city centres have suffered changes in their use, becoming cultural, social or representative centres. This thesis attempts the analysis of the constructive systems employed in tobacco industrial architecture, from drying sheds to factories. The drying sheds are an example of bioclimatic industrial architecture. The factories are a typology that have successfully adapted to new uses. Industrial architecture uses a language that follows the advances in industrialization, anticipating new materials and structures, and merging the complex relationships established among products, human beings, space and locations. These buildings were promoted extensively in the country. They are characterized by technological architectural sociological and landscaping innovations. They are considered as important examples of the evolution and the implementation of construction techniques (building materials and structures). They are also considered as examples of innovation in the building typology, in their economic structure and in the technologies that they have applied. The settings in which the drying sheds are placed have an important influence in them. They cannot be considered as isolated elements. Instead, there is a close relationship between drying sheds and the surroundings in which they are located. Drying sheds’ hygrotermal and environmental conditions are analyzed in this thesis to compare them with the values of human comfort and find suitable relationships and parameters. All the drying sheds that have been analyzed are constructed with brick. This implies a consideration of “zero degree” for both the construction and the composition of the architectural process. The detailing - entails making all the accumulative processes explicit as the brick walls are left exposed. This minimal component allows a wide range of options that are never random but based on the logic of the way in which it is combined. The “sincerity” in the exposition of material, displaying them in their very nature and showing how they are really used, is a basic characteristic of industrial architecture, and it is even more expressive in these types of buildings. The walls of the drying sheds undergo a permeability assessment in order to determine the degree of ventilation and orientation, the lattice pattern used and the overall volume. This specific conditioning system can serve as a resource for other buildings, and consequently, it could be transferred to other uses within a two-pronged approach: -Climatically adapted architecture that takes into account the surroundings. -Architecture as a generator of specific climatic conditions indoors. Drying sheds’ main purposes / aims deal with how to provide shade, ventilation and a covered space as well as permeability. The industrial architecture must be recognized as historical valuable buildings due to its intrinsic and distinctive characteristics. Knowing the productive structure, allow us to make a proper analysis of these buildings, since the basic aim, is to understand the spatial organization indoors. Factories did not come close to the tobacco production, with the exception of Cádiz and Palazuelo, where there are sheds and tobacco croplands nearby. The main reason for this separation is that the process of obtaining tobacco has two processes: the primary process and the secondary process. In the primary process tobacco leaves are left to dry. In the secondary process, previously manufactured tobacco allocated in the factories where the weather conditions are not important. This fact determines that in the climate areas where this study tales place there are some cases in which we can find both factories and drying sheds, and others where there are either factories or drying sheds only. The location of these factories met various demands, being the most outstanding the ones related to geographic, strategic and political reasons. In most factories the choice of its location was often linked to the incoming of raw goods, mainly delivered through waterways –it is the case of Seville,) and by land, using railways. The location of the factories was linked to political reasons in only two cases Madrid and Logroño, which are the only ones that are not placed near the coast. The one in Madrid was built due to its political centrality and because geographically speaking, it was the reference landmark of means of land and rail transports. Many factories, in fact, were settled nearby rail stations. For the factory in Logroño, only political reasons were taken into consideration. I should like to close by undertaking a comparative study of factories in Seville, Madrid and San Sebastian. There are a number of reasons to substantiate this choice: -The factory in Seville was historically speaking the first that was built and the most important one. -The factory in Madrid was the most important one administratively. This factory was the headquarters as well as being, after Seville, the one which provided a model for other factories. -The factory in San Sebastian is the biggest in the North of Spain. The analysis carried out are related to the volume of the buildings and the surface areas of the courtyards, the surface of the roofs, the permeability of the walls and the openings of the façade, the orientation and the sun exposure, the indoor spatial distribution and organization and evolution of the uses (formerly and currently) I observe that in most of these factories there has been a change in the use of the buildings, from industrial cultural purposes. These buildings can be considered as adaptable infrastructures based on a combination of architectural practicability, sustainability and functionality.

Análisis de la degradación, desintegración y biodegradabilidad de bolsas de poliéster y almidón en compostaje de residuos urbanos: escalas de laboratorio e industrial

El principal objetivo de esta tesis es verificar que las bolsas biodegradables de copoliéster (PBAT) con base de almidón (UNE 13432: 2001) alcanzan los niveles de degradación y desintegración requeridos para su certificación (%D= ≥ 90%), medido en condiciones reales de compostaje industrial. Para lograr mayor representatividad, los ensayos se han realizado en dos plantas de tratamiento de residuos urbanos en las que se aplican las técnicas de compostaje más comunes en el ámbito europeo y nacional, pila y túnel, mediante el compostaje de la FORSU. Se llevaron a cabo dos tipos de ensayos. Por un lado se realizó un ensayo escala de laboratorio (ISO 14855), orientado como indicador de la biodegradabilidad del polímero en el formato bolsa comercializado. Por otro lado, se desarrollaron una batería de ensayos realizados en dos plantas de compostaje de residuos urbanos: el Centro de Tratamiento de Residuos de Torija (Ávila), que realiza el compostaje mediante pila volteada, y el Centro de Tratamiento de Residuos de Arenas de San Pedro (Ávila), que realiza el compostaje en túnel. Para la obtención de resultados se han contrastado parámetros como el porcentaje de biodegradación (%B), el porcentaje de desintegración (%D), degradación superficial de las muestras, calidad de la FORSU inicial (caracterizaciones y análisis físico-químico) y calidad del MB final (análisis físico-químico e IG). Atendiendo al objetivo general se demuestra que las bolsas de copoliéster con base de almidón certificadas (UNE EN 13432:2001) han alcanzado el 94,37% ± 0,007% de desintegración en la planta de compostaje de FORSU con pila volteada; y el 86,36% ± 0,151% en la planta de compostaje de FORSU con túnel estático. A pesar de la aparente diferencia, el resultado del análisis concluye que no existen diferencias estadísticamente significativas entre técnicas de compostaje. La presencia de impropios y el contendido de metales pesados en la FORSU no han influido en la desintegración de las bolsas de estudio. En cambio, se ha detectado una influencia estadísticamente significativa entre el contenido de materia orgánica total y de nutrientes de la FORSU y el porcentaje de desintegración de las muestras. No se detectado una relación estadísticamente significativa entre la presencia de bolsas de estudio en las concentraciones definidas, y la calidad del MB, medido mediante el análisis físico-químico, microbiológico y el IG del MB. La concentración de los metales pesados en la mayoría de las muestras de material bioestabilizado cumplió con los límites establecidos para la categoría A, aplicable al “compost” procedente de la fracción orgánica recogida de forma separada según el RD 506/2013 de productos fertilizantes. También se detectó fitotoxicidad alta (FA) según la metodología y criterios de valoración definidos. Esta fitotoxicidad no está relacionada con la presencia de las bolsas de estudio sino con la calidad de la FORSU de partida y/o con los productos liberados durante el proceso de compostaje. ABSTRACT The main objective of this thesis is to verify that the copolyester (PBAT) starch based (UNE 13432: 2001) biodegradable bags reach levels of degradation and disintegration required for it´s certification (% D = ≥ 90%), measured in terms of real industrial composting. The tests were performed at two municipal solid waste (MSW) treatment plants, where the most common composting techniques applied at European and national level were represented, windrow and tunnel. Two types of tests were carried out: First, a laboratory scale test (ISO 14855), as an indicator of the polymer biodegradation of the commercialized bag format. Second, a battery of tests was conducted at two MSW composting plants, Waste Treatment Center of Torija (Guadalajara), that makes compost by turned pile, and the Waste Treatment Center of Arenas de San Pedro (Ávila), where makes compost by static tunnel. To obtain the results, the parameters such as the biodegradation percentage (% B), the disintegration percentage (% D), surface degradation of the samples, the initial quality of FORSU (characterizations and physico-chemical analysis) and bioestabilithated material (MB) quality (physico-chemical analysis and IG) have been compared. In reference to the general aim It shows that the copolyester starch based certified (UNE-EN 13432) bags have reached 94.37% ± 0.007% of disintegration in the composting turned pile; and 86.36% ± 0.151% in the static tunnel. Despite the apparent difference, the result of the analysis concludes that there are no statistically significant differences between composting techniques. The presence of non-compostable materials and the heavy metals content in the FORSU has not affected in the disintegration of the bags. Instead, It has been detected a statistically significant influence over the total organic matter content and nutrient content in the FORSU and the samples disintegration percentage. A statistically significant relationship between the bag presence in the defined concentrations and the quality of MB measured by physical-chemical analysis, microbiological analysis and IG of the MB is not detected. The concentration of heavy metals in most MB samples was within the limits of A-Class, applicable to "compost" from organic waste collected separately according to RD 506/2013 of fertilizers. High phytotoxicity (FA) was also detected according to the methodology and evaluation defined. The phytotoxicity is not related to the presence of bags but it is with the FORSU initial quality and/or with the products released during the composting process.

Analysing the complexity of the model-based decision making processes within the industrial management context

PURPOSE The decision-making process plays a key role in organizations. Every decision-making process produces a final choice that may or may not prompt action. Recurrently, decision makers find themselves in the dichotomous question of following a traditional sequence decision-making process where the output of a decision is used as the input of the next stage of the decision, or following a joint decision-making approach where several decisions are taken simultaneously. The implication of the decision-making process will impact different players of the organization. The choice of the decision- making approach becomes difficult to find, even with the current literature and practitioners’ knowledge. The pursuit of better ways for making decisions has been a common goal for academics and practitioners. Management scientists use different techniques and approaches to improve different types of decisions. The purpose of this decision is to use the available resources as well as possible (data and techniques) to achieve the objectives of the organization. The developing and applying of models and concepts may be helpful to solve managerial problems faced every day in different companies. As a result of this research different decision models are presented to contribute to the body of knowledge of management science. The first models are focused on the manufacturing industry and the second part of the models on the health care industry. Despite these models being case specific, they serve the purpose of exemplifying that different approaches to the problems and could provide interesting results. Unfortunately, there is no universal recipe that could be applied to all the problems. Furthermore, the same model could deliver good results with certain data and bad results for other data. A framework to analyse the data before selecting the model to be used is presented and tested in the models developed to exemplify the ideas. METHODOLOGY As the first step of the research a systematic literature review on the joint decision is presented, as are the different opinions and suggestions of different scholars. For the next stage of the thesis, the decision-making process of more than 50 companies was analysed in companies from different sectors in the production planning area at the Job Shop level. The data was obtained using surveys and face-to-face interviews. The following part of the research into the decision-making process was held in two application fields that are highly relevant for our society; manufacturing and health care. The first step was to study the interactions and develop a mathematical model for the replenishment of the car assembly where the problem of “Vehicle routing problem and Inventory” were combined. The next step was to add the scheduling or car production (car sequencing) decision and use some metaheuristics such as ant colony and genetic algorithms to measure if the behaviour is kept up with different case size problems. A similar approach is presented in a production of semiconductors and aviation parts, where a hoist has to change from one station to another to deal with the work, and a jobs schedule has to be done. However, for this problem simulation was used for experimentation. In parallel, the scheduling of operating rooms was studied. Surgeries were allocated to surgeons and the scheduling of operating rooms was analysed. The first part of the research was done in a Teaching hospital, and for the second part the interaction of uncertainty was added. Once the previous problem had been analysed a general framework to characterize the instance was built. In the final chapter a general conclusion is presented. FINDINGS AND PRACTICAL IMPLICATIONS The first part of the contributions is an update of the decision-making literature review. Also an analysis of the possible savings resulting from a change in the decision process is made. Then, the results of the survey, which present a lack of consistency between what the managers believe and the reality of the integration of their decisions. In the next stage of the thesis, a contribution to the body of knowledge of the operation research, with the joint solution of the replenishment, sequencing and inventory problem in the assembly line is made, together with a parallel work with the operating rooms scheduling where different solutions approaches are presented. In addition to the contribution of the solving methods, with the use of different techniques, the main contribution is the framework that is proposed to pre-evaluate the problem before thinking of the techniques to solve it. However, there is no straightforward answer as to whether it is better to have joint or sequential solutions. Following the proposed framework with the evaluation of factors such as the flexibility of the answer, the number of actors, and the tightness of the data, give us important hints as to the most suitable direction to take to tackle the problem. RESEARCH LIMITATIONS AND AVENUES FOR FUTURE RESEARCH In the first part of the work it was really complicated to calculate the possible savings of different projects, since in many papers these quantities are not reported or the impact is based on non-quantifiable benefits. The other issue is the confidentiality of many projects where the data cannot be presented. For the car assembly line problem more computational power would allow us to solve bigger instances. For the operation research problem there was a lack of historical data to perform a parallel analysis in the teaching hospital. In order to keep testing the decision framework it is necessary to keep applying more case studies in order to generalize the results and make them more evident and less ambiguous. The health care field offers great opportunities since despite the recent awareness of the need to improve the decision-making process there are many opportunities to improve. Another big difference with the automotive industry is that the last improvements are not spread among all the actors. Therefore, in the future this research will focus more on the collaboration between academia and the health care sector.

Educación Superior de la Ingeniería Industrial en el Perú: propuesta de un modelo educativo desde las competencias

El objetivo del presente trabajo de investigación es diseñar un Modelo de Educación que permita formar ingenieros industriales en Perú que sean capaces de enfrentar los retos modernos de fuerte y sostenido crecimiento económico y social. Las necesidades que se han generado a lo largo de los últimos años llevan a identificar que una gran carencia es el poco dominio del concepto, naturaleza y gestión de un proyecto y la marcada ausencia de habilidades humanas y funcionales al momento de ejercer la profesión; entendiendo proyecto como “Un esfuerzo temporal que se lleva a cabo para crear un producto, servicio o resultado único. La naturaleza temporal de los proyectos indica un principio y un final definidos. El final se alcanza cuando se logran los objetivos del proyecto o cuando se termina el proyecto porque sus objetivos no se cumplirán o no pueden ser cumplidos, o cuando ya no existe la necesidad que dio origen al proyecto…. los proyectos pueden tener impactos sociales, económicos y ambientales susceptibles de perdurar mucho más que los propios proyectos.”1. Entonces, formularnos la hipótesis que es posible tener un modelo educativo para la Ingeniería Industrial de Perú que permita y estimule alcanzar estas características tan reclamadas por la sociedad, confiando desde el inicio que su diseño y empleo tendrá fuerte repercusión tanto en el desarrollo personal de los estudiantes, como en el social y económico, por las habilidades y condiciones que serán capaces de desplegar los egresados en sus ámbitos de acción laboral. Para lograr el objetivo se ha hecho una definición de la identidad de la universidad latinoamericana y una verificación de si es posible o no tomar modelos y experiencias de otros lugares y trasladarlos con éxito a escenarios nuevos y distintos. Luego, se han determinado las tendencias más fuertes en la formación de ingenieros industriales en los contextos más exitosos actualmente. Para definir esas habilidades tan reclamadas por el sector público y privado de la sociedad, se busca y define una codificación de competencias genéricas que permite tener un ingeniero moderno bien perfilado para las exigencias globales. Los pasos finales son determinar el Modelo para la Educación Superior de la Ingeniería Industrial de Perú desde las Competencias (MESIC) a partir de novedosos enfoques para la educación como la contextualización, la gestión del conocimiento experto y experimentado, el enfoque socioformativo y la definición de Aspectos Clave del modelo antes de iniciar una planificación curricular de ingeniería. Al final se muestra una aplicación del modelo llegando a detalles de definición de competencias muy interesantes y a la necesidad de contar con un sistema de aseguramiento de calidad de la gestión curricular. Al término de la investigación concluimos que es posible definir un modelo apropiado para formar ingenieros industriales en Perú desde las competencias, capaces de enfrentar los modernos retos locales y globales. También determinamos que el proceso no puede ser impuesto, debe pasar por un transitorio periodo de adecuación de docentes y alumnos y requiere de compromiso, pues se suele enfocar este cambio como una forma de desestimar todo lo anterior, cuando debe entenderse que son procesos complementarios, ya que los importantes logros con clases magistrales y resolución de problemas son evidentes y se trata de estilos diferentes de encarar la educación. El resultado de la imposición puede ser devastador para algunos estudiantes y frustrante para algunos docentes, consecuencias que no se desean y deben evitarse. La aplicación se realiza en una universidad del norte de Perú, la Universidad de Piura, y puede observarse en el último capítulo de este trabajo. ABSTRACT The main objective of this research is to find an Educational Modell in order to train industrial engineers in Peru who are able to face modern challenges of strong and sustained economic and social growth. Over recent years the generated needs have led to understand that a major weakness in our professionals is the poor skills in project management and the marked absence of functional and human skills when exercising the profession. This diagnose has led to formulate the hypothesis that it is possible to have an educational model for Peru Industrial Engineering that allows and encourages to achieve these features which are claimed by society. A project which we trust will have a strong impact from the beginning on both, personal development of students as well as in the social and economic conditions, considering the skills graduates will be able to deploy in their work fields. To achieve the goal first it was defined the identity of the Latin American university and verified whether it is possible or not to take models and experiences elsewhere and move successfully to new and different scenarios. Then there were determined the strongest trends in the industrial engineers training in currently successful contexts. In order to define these demanded skills by the public and private sectors of society, there are defined a set of generic skills that allows to have a modern engineer well profiled for global context. Considering these elements, a Model for Higher Education in Industrial Engineering from Peru Competence (MESIC)is proposed considering novel approaches to education such as territoriality, skilled and experienced knowledge management, socio - formative approach and set the definition of Key aspects of the model before starting a engineering curricular planning. Finally detailed records of an application of the model is shown through modern learning methodologies, development and assessment of skills and the need to have a quality assurance system for entire curriculum management. Through this research it can be concluded that it is possible to determine an appropriate model to train industrial engineers in Peru from the skills, in order to meet the modern local and global challenges. Results show that the process cannot be imposed, instead it must go through a transitional period of adaptation from teachers and students and requires commitment, focusing that this change usually is a way to dismiss the above, and is important to address that there are obvious achievements on education lectures and problem solving, and it should be understood that they are complementary processes. The result of change imposition can be devastating for some students and frustrating for some teachers, unwanted consequences and they should be avoided. The proposed model is applied at a university in northern Peru, the University of Piura, and the results can be seen in the last chapter of this work.

Systematic Process for Building a Fault Diagnoser Based on Petri Nets Applied to a Helicopter

This work presents a systematic process for building a Fault Diagnoser (FD), based on Petri Nets (PNs) which has been applied to a small helicopter. This novel tool is able to detect both intermittent and permanent faults. The work carried out is discussed from theoretical and practical point of view. The procedure begins with a division of the whole system into subsystems, which are the devices that have to be modeled by using PN, considering both the normal and fault operations. Subsequently, the models are integrated into a global Petri Net diagnoser (PND) that is able to monitor a whole helicopter and show critical variables to the operator in order to determine the UAV health, preventing accidents in this manner. A Data Acquisition System (DAQ) has been designed for collecting data during the flights and feeding PN diagnoser with them. Several real flights (nominal or under failure) have been carried out to perform the diagnoser setup and verify its performance. A summary of the validation results obtained during real flight tests is also included. An extensive use of this tool will improve preventive maintenance protocols for UAVs (especially helicopters) and allow establishing recommendations in regulations

System theory based hazard analysis applied to the process industry

Chemical process accidents still occur and cost billions of dollars and, what is worse, many human lives. That means that traditional hazard analysis techniques are not enough mainly owing to the increase of complexity and size of chemical plants. In the last years, a new hazard analysis technique has been developed, changing the focus from reliability to system theory and showing promising results in other industries such as aeronautical and nuclear. In this paper, we present an approach for the application of STAMP and STPA analysis developed by Leveson in 2011 to the process industry.

DA TERCEIRA REVOLUÇÃO INDUSTRIAL À PRODUÇÃO ENXUTA SEU IMPACTO NA INDÚSTRIA DE AUTOPEÇAS CASO: MAHLE METAL LEVE S/A

A presente dissertação teve como objetivo verificar as razões pelas quais a empresa Metal Leve cedeu o controle acionário a uma empresa concorrente de porte internacional e comparar a situação existente à época da sua desnacionalização e o estágio em que se encontra a nova controladora Mahle Metal Leve S. A. em termos de produção e gestão, após a reorganização produtiva. Esse processo de internacionalização produtiva acarretou modificações na empresa ensejando uma reestruturação da produção e da gestão e um novo círculo vicioso, constituindo as bases de um novo crescimento econômico, com um projeto estratégico de longo prazo, associado ao seu poder econômico, a sua capacidade gerencial e a sua tradição. O estudo está fundamentado em um conjunto de informações sobre os dois momentos, focalizando os resultados financeiros, aspectos gerenciais, liderança, capacidade competitiva e a evolução ao longo desses dois momentos comparados. Concluindo que não apenas o fenômeno da globalização da economia internacional tornou inevitável a cessão do controle acionário. Porém, também faltou visão estratégica para perceber as mudanças que inevitavelmente ocorriam a sua volta e que a nova controladora, a Mahler Metal Leve, trouxe uma competência gerencial que resultou em ganhos de produtividade e melhorou sua competitividade

DA TERCEIRA REVOLUÇÃO INDUSTRIAL À PRODUÇÃO ENXUTA SEU IMPACTO NA INDÚSTRIA DE AUTOPEÇAS CASO: MAHLE METAL LEVE S/A

A presente dissertação teve como objetivo verificar as razões pelas quais a empresa Metal Leve cedeu o controle acionário a uma empresa concorrente de porte internacional e comparar a situação existente à época da sua desnacionalização e o estágio em que se encontra a nova controladora Mahle Metal Leve S. A. em termos de produção e gestão, após a reorganização produtiva. Esse processo de internacionalização produtiva acarretou modificações na empresa ensejando uma reestruturação da produção e da gestão e um novo círculo vicioso, constituindo as bases de um novo crescimento econômico, com um projeto estratégico de longo prazo, associado ao seu poder econômico, a sua capacidade gerencial e a sua tradição. O estudo está fundamentado em um conjunto de informações sobre os dois momentos, focalizando os resultados financeiros, aspectos gerenciais, liderança, capacidade competitiva e a evolução ao longo desses dois momentos comparados. Concluindo que não apenas o fenômeno da globalização da economia internacional tornou inevitável a cessão do controle acionário. Porém, também faltou visão estratégica para perceber as mudanças que inevitavelmente ocorriam a sua volta e que a nova controladora, a Mahler Metal Leve, trouxe uma competência gerencial que resultou em ganhos de produtividade e melhorou sua competitividade