Optimizing Manufacturing Processes through Advanced Process Engineering Techniques: A Case Study of Energy Efficiency, Waste Reduction, and Environmental Sustainability: Review

Abstract

Manufacturing processes has evolved over the last century with the incorporation
of a lot of new concepts. The industry as today is faced with a growing demand
for higher quality products, tailored to specifications, energy efficient processes,
ecofriendly processes and increased process sophistication with fewer human
operations and much reliance on artificial intelligence. Thus, there is so much
reliance on technology, science, innovation, interdisciplinary research and
development (R&D) to either develop advanced manufacturing processes or
optimize the existing processes to achieve the desired goals. In this review study,
emphasis is placed on the various advanced process engineering techniques for
optimizing manufacturing processes. Advanced process engineering techniques
encompass a range of methodologies and tools used to optimize and improve
industrial processes across various fields, including chemical engineering,
manufacturing, pharmaceuticals, and biotechnology. These techniques leverage
on advanced computational methods, data analysis, optimization algorithms, and
innovative approaches to enhance process efficiency, reduce costs, minimize
waste, and ensure product quality. Optimizing energy use in industry contributes
to sustainable engineering by conserving resources, reducing emissions, and
promoting renewable usage, thus aligning with the global need for sustainable
development. Thus, from studies reviewed, process simulation using Aspen
HYSIS was adopted in optimizing the energy efficiency in SIBUR Petrochemical
Company, and it resulted in the recovery of over 25% of the overall energy
consumption, and an IRR greater than 25%. Other studies revealed that the
implementation of Just-in-time inventory (JIT) methodology results in waste
reduction. Lastly, a study shows that the adoption of eco-design strategies or
characteristic in a manufacturing process, influences enterprise sustainability
innovativeness.