Given the significant requirements for transforming and promoting the process industry, we present the major limitations of current petrochemical enterprises, including limitations in decision-making, production operation, efficiency and security, information integration, and so forth. To promote a vision of the process industry with efficient, green, and smart production, modern information technology should be utilized throughout the entire optimization process for production, management, and marketing. To focus on smart equipment in manufacturing processes, as well as on the adaptive intelligent optimization of the manufacturing process, operating mode, and supply chain management, we put forward several key scientific problems in engineering in a demand-driven and application-oriented manner, namely: ① intelligent sensing and integration of all process information, including production and management information; ② collaborative decision-making in the supply chain, industry chain, and value chain, driven by knowledge; ③ cooperative control and optimization of plant-wide production processes via human-cyber-physical interaction; and ④ life-cycle assessments for safety and environmental footprint monitoring, in addition to tracing analysis and risk control. In order to solve these limitations and core scientific problems, we further present fundamental theories and key technologies for smart and optimal manufacturing in the process industry. Although this paper discusses the process industry in China, the conclusions in this paper can be extended to the process industry around the world.
Process industries such as steel and petrochemical engineering are the pillar industry of national economy, which are the foundation to achieve “manufacturing prower” and the top 10 development areas of “Made in China 2025.” So far, the disharmony of equipment and process engineering in process industries results in the outstanding problems in safety and economic operation, such as high energy consumption and high failure rates of equipments. In this paper, the reasons are analyzed in design and construction, business management, government orientation and talent cultivation. Development strategies are put forward for greenization, intelligentization and remanufacture in service of equipments in process industries. Some strategies and policy proposals are also put forward for greening design and manufacture, intelligentized supervisory control of health and energy efficiency for equipment, and remanufacture in service.
China is going through an important historical stage as it transforms from a large country with manufacturing industry into a global manufacturing power. With the guidance of green development concept, China must explore strategic issues on advancing the coordinated development between manufacturing industry and ecological environment, for the harmonious coexistence between industrial civilization and ecological civilization. Green manufacturing is a critical focus in the construction of manufacturing power and in the transformation of production modes. Moreover, green manufacturing is an important part of green development. Green manufacturing contains low carbon development and circulation development. This paper elaborates on the scientific implications, targets and evaluation system of green manufacturing, on the basis of clarifying the relationship between green manufacturing and ecological civilization. The authors then put forward the strategic direction and major projects for green manufacturing, based on the achievements and difficulties of the current development. Policy implications are provided from the aspects of top-level design, team construction, innovation system, service platform, system and mechanism, and international cooperation.
Manufacturing industry is the key carrier of the technological innovation. The technological innovation is the key force for the development of manufacturing industry. The manufacturing industry in China has experienced the fast development since reform and opening up, but in general, the industry appears to be “large but not strong”. The research utilizes a scientific analysis to detect environments the development of manufacturing in China facing to and capabilities of the innovation. It is critical to persist the principle of “independent innovation, intelligence leaded, green development, and breakthrough in key areas” to realize the innovation-driven development of China Manufacturing. The core of the developments must be to improve the capability of independent innovation, and the main path is to develop the manufacturing digitalized, networked, and intelligentialized. It is important to develop green manufacturing with energy efficiency increased and friendly relationship with environments. Firstly, breakthroughs in key products in the key fields and key manufacturing technology can be realized, and the transformation and upgrading of manufacturing industry can be realized. Finally, we will realized the historic leap of China Manufacturing from high capacity to high capability.
This paper presents initial findings on a current approach in public policy to promote green technology diffusion using innovative policy measures, through the case of the electric motor upgrading project (EMUP), and examines the degree of success of local governments in their effort to encourage the adoption of high efficiency motors (HEMs). The barriers to green technology diffusion are explored to showcase the challenges faced by local implementer. This research demonstrates the successes of various regions with an emphasis on Dongguan City, which has enjoyed great success using subsidies and financial tools to promote the use of energy performance contracts as an innovative financing mode. Finally, this article analyzes the methods and outcomes of the EMUP, thus far, in order to explain the reasons behind the success of this initial phase of implementation. Further research will be needed to monitor the progress of this initiative. This article summarizes the policy system and the new model will help to promote the development of energy conservation and environmental protection industry in the strategic emerging industries.
The rapid development of industrial automation has brought favorable requirements for the chemical enterprises to carry out comprehensive automation. This article brings forward the three-strata structure of the comprehensive automation, describes it in concepts, and discusses the key problems which should be paid attention to during its process. Finally, an example project is briefly introduced on the basis of the understanding which is acquired through practical implementation of comprehensive automation for chemical enterprises.
Based on the in-depth analysis of features of the process industry, the state of art of its operation control, and the global development of intelligent manufacturing, a new mode of intelligent manufacturing for the process industry, i.e., smart and optimal manufacturing, is proposed. After analysis of the development situation of the existing three-tier architecture (consisting of enterprise resource planning, manufacturing execution system, and process control system) and the control and management informatization system adopted by process enterprises, a smart and optimal manufacturing framework and prospects for future process enterprises are presented, followed by the analysis of key generic technologies that are critical for the successful deployment of intelligent manufacturing in the process industry. The fundamental challenges and open scientific problems to be addressed jointly by the communities of automation, computer and communication, and data science are also presented. Moreover, suggestions on the future development and deployment of smart and optimal manufacturing in the process industry are offered, include emphasizing the strategic position of the process industry, actualizing the strategic planning and top-level design.
Smart manufacturing is critical in improving the quality of the process industry. In smart manufacturing, there is a trend to incorporate different kinds of new-generation information technologies into process-safety analysis. At present, green manufacturing is facing major obstacles related to safety management, due to the usage of large amounts of hazardous chemicals, resulting in spatial inhomogeneity of chemical industrial processes and increasingly stringent safety and environmental regulations. Emerging information technologies such as artificial intelligence (AI) are quite promising as a means of overcoming these difficulties. Based on state-of-the-art AI methods and the complex safety relations in the process industry, we identify and discuss several technical challenges associated with process safety: ① knowledge acquisition with scarce labels for process safety; ② knowledge-based reasoning for process safety; ③ accurate fusion of heterogeneous data from various sources; and ④ effective learning for dynamic risk assessment and aided decision-making. Current and future works are also discussed in this context.