Reactivity effects of inorganic content in biomass gasification: A review

This review article discusses the effects of inorganic content and mechanisms on raw biomass and char during gasification. The impacts of the inherent inorganics and externally added inorganic compounds are summarized based on a literature search from the most recent 40 years. The TGA and larger-scale studies involving K-, Ca-, and Si-related mechanisms are critically reviewed with the aim of understanding the reaction mechanisms and kinetics. Differences between the reaction pathways of inorganic matter, and subsequent effects on the reactivity during gasification, are discussed. The present results illustrate the complexity of ash transformation phenomena, which have a strong impact on the design of gasifiers as well as further operation and process control. The impregnation and mixing of catalytic compounds into raw biomass are emphasized as a potential solution to avoid reactivity-related operational challenges during steam and CO2 gasification. This review clearly identifies a gap in experimental knowledge at the micro and macro levels in the advanced modelling of inorganics transformation with respect to gasification reactivity.</p

Special Issue: Biochemical and thermochemical conversion processes of lignocellulosic biomass fractionated streams

Global consumption of materials such as forest resources, fossil fuels, earth metals and minerals are expected to double in the next 30 years, while annual waste production is estimated to increase by approximately 70% by 2050 [1]. Keeping the resource consumption within planetary boundaries, we strive to minimize the carbon and environmental footprint and concurrently double the waste material use in the coming decades. Preventing food waste from being generated could have a major impact on waste collection systems and on the capacity of bio-waste management facilities worldwide [2]. Therefore, sustainable food waste management is a key part of any green business strategy to convert food waste into green fuels

An implementation model for digitisation of visual management to develop a smart manufacturing process

Purpose – This paper aims to introduce a model using a digital twin concept in a cold heading manufacturing and develop a digital visual management (VM) system using Lean overall equipment effectiveness (OEE) tool to enhance the process performance and establish Fourth Industrial Revolution (I4.0) platform in small and medium enterprises (SMEs). Design/methodology/approach – This work utilised plan, do, check, act Lean methodology to create a digital twin of each machine in a smart manufacturing facility by taking the Lean tool OEE and digitally transforming it in the context of I4.0. To demonstrate the effectiveness of process digitisation, a case study was carried out at a manufacturing department to provide the data to the model and later validate synergy between Lean and I4.0 platform. Findings – The OEE parameter can be increased by 10% using a proposed digital twin model with the introduction of a Level 0 into VM platform to clearly define the purpose of each data point gathered further replicate in projects across the value stream. Research limitations/implications – The findings suggest that researchers should look beyond conversion of stored data into visualisations and predictive analytics to improve the model connectivity. The development of strong big data analytics capabilities in SMEs can be achieved by shortening the time between data gathering and impact on the model performance. Originality/value – The novelty of this study is the application of OEE Lean tool in the smart manufacturing sector to allow SME organisations to introduce digitalisation on the back of structured and streamlined principles with well-defined end goals to reach the optimal OEE </p

Implementation of an ISO 50001 energy management system using Lean Six Sigma in an Irish dairy: a case study

This article aims to optimise energy use and consumption by integrating Lean Six Sigma  methodology with the ISO 50001 energy management system standard in an Irish dairy plant operation. Design/methodology/approach – This work utilised Lean Six Sigma methodology to identify methods to measure and optimise energy consumption. The authors use a single descriptive case study in an Irish  dairy as the methodology to explain how DMAIC was applied to reduce energy consumption.Findings – The replacement of heavy oil with liquid natural gas in combination with the new design  of steam boilers led to a CO2 footprint reduction of almost 50%. Practical implications – A further longitudinal  study would be useful to measure and monitor the energy management system progress  and carry out more casestudies on LSS integration with energy management systems across the dairy industry. Originality/value – The novelty of this study is the application of LSS in the dairy sector as an enabler of a greater energy-efficient facility, as well as the testing of the DMAIC approach to meet a key objective for ISO 50001 accreditation</p

A review of lean adoption in the Irish medTech industry

There have been many literature reviews carried out on Lean implementation in larger organisations with specific focus on the automobile industry. Lean implementation in the medical device industry has not been extensively investigated. Thus, this research endeavored to analyse the benefits of Lean, tools utilised and challenges and results of Lean implementation in Medtech companies. This article aims to bridge a gap in the literature by reviewing the literature that discusses Lean implementation in MedTech companies in Ireland with a perspective of identifying the benefits and challenges faced. The quantitative methodology allows us to review the comprehensive numbers and data which were collected from 20 Enterprise Ireland MedTech case studies. There are very few published case studies in the literature on Lean due to the highly regulated nature of MedTech sector and the vast array of medical devices, which are often under privacy and confidentiality constraints. The results showed that integration of Lean has brought benefits to companies by increasing productivity and product quality, optimised cost, and time. An inclusive discussion of Lean tools for Lean implementation within MedTech was established and suggestions for future research orientations are thus provided

Application of Design for Lean Six Sigma to strategic space management

 Purpose – This paper outlines how Design for Lean Six Sigma methods aided a medical device manufacturing company in developing a new strategic space management and approval process for its manufacturing site. Design/methodology/approach – The project demonstrates the application of the Design for Lean Six Sigma and structured Define, Measure, Analyse, Design, and Verify methodology in designing and implementing a process that enables the case study manufacturing site to improve its space utilisation and free up space. Findings – The project was validated in one manufacturing department, and the Design for Lean Six Sigma methodology resulted in creating 15% new space for that area, with opportunities identified to free up 44.7% of the total manufacturing floor space and realise over V2.2 million cost savings as well as start to manufacture new products launched. Research limitations/implications – The manuscript highlights for the first time how the Design for Lean Six Sigma methodology can be utilised for space utilisation and can be leveraged by other manufacturers. The current study’s limitations are that it is a single-site case study application. Future longitudinal case studies on Design for Lean Six Sigma application in more manufacturing space utilisation projects would be useful. This study has implications for identifying best practices for Design for Lean Six Sigma methodology application in the device industry, thus improving the state of the art for introducing new manufacturing lines. Originality/value – This is the first published work to utilise Design for Lean Six Sigma methodology for space utilisation in a medical device company. This review will provide medical devices and other manufacturing organisations with recommendations on utilising Design for Lean Six Sigma and design for improved space utilisation to reduce costs. </p

Life cycle assessment of renewable reductants in the ferromanganese alloy production: a review

This study examined the literature on life cycle assessment on the ferromanganese alloy production route. The environmental impacts of raw material acquisition through the production of carbon reductants to the production of ferromanganese alloys were examined and compared. The transition from the current fossil fuel-based production to a more sustainable production route was reviewed. Besides the environmental impact, policy and socioeconomic impacts were considered due to evaluation course of differences in the production routes. Charcoal has the potential to substantially replace fossil fuel reductants in the upcoming decades. The environmental impact from current ferromanganese alloy production can be reduced by ≥20% by the charcoal produced in slow pyrolysis kilns, which can be further reduced by ≥50% for a sustainable production in high-efficient retorts. Certificated biomass can ensure a sustainable growth to avoid deforestation and acidification of the environment. Although greenhouse gas emissions from transport are low for the ferromanganese alloy production, they may increase due to the low bulk density of charcoal and the decentralized production of biomass. However, centralized charcoal retorts can provide additional by-products or biofuel and ensure better product quality for the industrial application. Further upgrading of charcoal can finally result in a CO2 neutral ferromanganese alloy production for the renewable power supply

A benefit costing process for lean six sigma programs

Purpose – This study aimed to bridge the gap between the financial measurement of process improvement ideas and Lean Six Sigma measurements. It was required to increase employee engagement in process improvement initiatives. Design/methodology/approach – Through both a practical and theoretical application of the Design for Lean Six Sigma methodology, the researcher was able to design a process and a benefit measuring methodology that was acceptable by finance and aligns with the benefits expected from the elimination of the Lean wastes. Findings – The project found that benefit measurement methodology is not understood by most employees, which leads to a lack of engagement in working on improvements. The result of the study was a model for employees to identify and quantify these benefits. This has resulted in a model for cost-benefit analysis aligning financial costs with non-value add waste costs and cost of poor-quality costs resulting in increased process improvement ideas and activity. Research limitations/implications – While this study was limited to one company, applying this methodology could benefit any company experiencing the same difficulties. Originality/value – This is one of the first studies to try and cost the benefits of LSS projects both from an organisational and generic viewpoint.</p

Implementing a customised Lean Six Sigma methodology at a compound animal feed manufacturer in Ireland

This study aims to propose a tailored Lean Six Sigma framework providing an  accessible Lean Six Sigma methodology for compound feed manufacturers  with the aim of mitigating rising costs and increasingly complex demands from customers.Design/methodology/approach A Lean Six Sigma framework was designed combining Lean value stream mapping and Six Sigma structured  problem-solving with a case study in an Irish compound feed manufacturer Findings The study found that the Lean Six Sigma implementation framework provided a simplified approach, which fitted the resource availability within compound feed manufacturing Research limitations/implications The study is limited by the constraints of a sole case study in providing  empirical evidence of the effectiveness of the framework. Nevertheless,  a conceptual Lean Six Sigma model is proposed, which will assist compound  feed manufacturers implementing a continuous improvement approach. Originality/value This paper proposes a simplified approach to the implementation  of Lean Six Sigma in agricultural compound feed manufacturers and in small and medium-sized organisations. This is the first such study in Ireland and  will add to the body of work on Lean in agriculture and aid other agri-businesses and compound feed manufacturers in understanding how Lean Six Sigma can benefit</p

Charcoal as an alternative reductant in ferroalloy production: A review

This paper provides a fundamental and critical review of biomass application as renewable reductant in integrated ferroalloy reduction process. The basis for the review is based on the current process and product quality requirement that bio-based reductants must fulfill. The characteristics of different feedstocks and suitable pre-treatment and post-treatment technologies for their upgrading are evaluated. The existing literature concerning biomass application in ferroalloy industries is reviewed to fill out the research gaps related to charcoal properties provided by current production technologies and the integration of renewable reductants in the existing industrial infrastructure. This review also provides insights and recommendations to the unresolved challenges related to the charcoal process economics. Several possibilities to integrate the production of bio-based reductants with bio-refineries to lower the cost and increase the total efficiency are given. A comparison of challenges related to energy efficient charcoal production and formation of emissions in classical kiln technologies are discussed to underline the potential of bio-based reductant usage in ferroalloy reduction process