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EngineeringSchool, USAC. .
TECHNICAL
ENGLI5H
Universidad de San Carlos de Guatemala
Engineering School
Technical English Booklet
Second Edition
UNI VERSI DAD DE SAN CARL OS DE GUATEMAL A
FACUL TAD DE I NGENI ER A
Technical English 3
lnformation contained in this work has been obtained by
gathering information fromsources believedto bereliable.
However, neither the sites nor the authors guarantee the
accuracy or completeness of any nformation published
herein and neither the Technical Language Area not its
assistants sha11beresponsible forany errors, ornissions, or
damages arlsing'out of use of this information. This work
is gathered with the understanding that the topies are
supplying information but are not attempting to render
engineering or other professonal services. I r such services
are required, the asaistance of an appropriate professional
should besought.
AWARENESS / ACKNOWLEDGMENT
Industrial
Industrial
Special thanks to:
Gustavo AdolfoLpez Lpez
Otto Leonel Cuellar Lque
lng. Carlos Leonel Muoz
Inga. Tatiana Vallejo
Mara Andr Cruz
Octavo Ciraiz Azurdia
Otto Enrique Garca
Industrial
Electrnica
Industrial
Electrnica
Electrnica
CONTRIBUTORS
It has been nteresting toiookat thereal applications this newcurrculum
can lead, 1t wakes up the creativity, reasoning, and awareness of
development indifferent areas of engineering. It is donethrough problem
solvingproposed inclasses and developedintheir fieldof work, enhancing
engineering techniques. Most o the projects of the course can beseen at
You'Tubebyjust searching under Technical EnglishUSAC.
Itis advice to make a revision every two years, and thanks to the
flexibility of the program, it will allowto make different changes mthe
themes studied as it isdoneinthis secondedition.
The second edition of the Technical English Book1etwas collected as a
gude to fulfill the objectives proposed in the restructuring of the
currculum of the course and the continuous improvement. This new
currculum was designed by Soraya Martnez, coordinator of the English
Section of tbe Engineering School, and developed with the help of the
different contributors that have worked as assstants at the area during
theyears of 2007 and 2008; ths second edition has been updated bythe
group that has workedfrom2009 till today. Each of the assistants has a
different specialization inthe fieldof engineering, soit helped towork ina
multidisciplinary environment.
After the currculum was finished, it was reviewedand authorized by the
Boardof Directoraof theEngineering School whodecidedtoimplement the
newcurrculum sincethefirst semester 2008.
PREFACE
Listeningfor specificinformation.
LJSTENING
Itincludes lectures, technical language fromvarious contexts. Listening
strategies that include summarizing main ideas, making inferences, and
giveopinions.
SPEAKING
This section inc1udes newtechnical words that the students have to learn
foreachreading,
VOCABULARY
Everytheme isorganized around grammatcal topics. Itistried topresent
grarnmar incontexto
GRAMMAR
Thethemes wereselected based inthe analysis o the currculum of each
career, and selecting the courses incommon. TheBooklet No.1covers the
basic sciences or the common area. The Booklets No. II and III cover the
courses o the mid term currculum, it means the courses of the fourth,
fifthand sixth semester. TheBooklet IV covers courses of theprofessional
areas specially {heones focusedon the development of managerial skills,
neededby thedifferent careers intheschool.
THEMES
The technical English booklet uses high interest themes to integrate
speaking, grarnrnar, vocabulary, pronunciation, listening, reading, and
writing. Thereisastrong focusonboth accuracy and fluency. Itincludes
real life situation that leads toameaningfullearning.
SYLLABUS ANn APPROACH
It is important for teachers to adapt the course materaIs to the needs,
interest, andlearningstylesof their students.
Assessment must be dcne through oral quizzes, written quizzes and
developmentofprojects.
lt helps to use correct formand rnechanics, use coherent structure,
edition, andrevisiontocreateafinal draft.
WRITING
lt emphaslzes reading strategies such as skrnming, scanning, guessing
meaningfromcontext, understanding the structure and organizationof a
text, increasingreadingspeed,
READING
To THE TEACHERS
1
Leanmanufacturing is avariaton on the theme of efficiency basedon optimizing flow; it is a
present-day instance of the recurring theme in human history toward increasing efflciencv,
decreasingwaste, and using empirical methods to decide what matters, rather than uncritically
acceptingpre-existing ideas.
Basically, lean is centered around
creatingmore value with less work. Lean
manufacturing is a generic proces.s
management philo.sophy derived mostly
from the Toyota Production System(TPS)
(hence the terrn Toyotism is also prevalent)
and identified as Lean only in the 1990s. It is
renowned for its focus on reduction of the
original Toyota seven wastes in order to
improve overall customer value, but there
are varyingperspectives on how this 5 S best
achieved.
Lean manufacturing or lean
production, which is often known simply as
Lean, is a production practice that considers
theexpenditure of resourcesfor anygoal other
thanthecreation of value for the endcustomer
to be wasteful, and thus a target for
elimination. Working from the perspective of
the customer who consumes a product or
service, value is defined as any action or
processthat a customer would be willing to
payforo
LEAN MANUFACTURING
GIntroduction
TECHNICAL ENGLlSH 3 ' 2011 USAC
Thefour goalsof lean manufacturing systemsare to:
Improve quality: In order to stay
competitive in today's marketplace, a
company must understand its customers'
wants and needs and designprocessesto
meet their expectations and
requirements.
Eliminate waste: Waste is anyactivity that
consumes time, resources, or space but
Lean Manufacturing Goals
Murl: is a J apanese term for overburden, unreasonableness or absurdity, which has become
popularized inthe West byits useasakeyconcept in the Toyota Production System.
Mura: istraditional general J apanesetermfor unevenness, inconsistencyin physical matter or human
spiritual condition.
Theoriginal sevenmuda are:
Transportaton (moving products that is not actually required to perform the processing)
Inventory (al!components, work in processandfinished product not beingprocessed)
Moton (people or equipment moving or walking more than is required to perform the
processing)
Waitng (waiting for the next production step)
Overproduction (production aheadof demand)
Over Processing(dueto poor tool or product designcreating activity)
Defects(the effort involved in inspectingfor andfixing defects)
Muda: is atraditional general J apanesetermfor anactivity that iswasteful anddoesn't addvalue or is
unproductive andit is alsoakeyconcept inthe Toyota Production System(TPS).
The elimination of waste isthe goal of lean, andToyota defined three broadtypes of waste:
Muda
Mura
Muri
TECHNICAL ENGLlSH 3 2011 US/,
3
Theeoreof leanis founded onthe concept of continuous product and processimprovement and
theeliminationof non-valueaddedactivities. IITheValue addingactivities are simply onlythose things
the customeris willing to pay for, everything else is waste, and should be eliminated, simplified,
reduced,or integrated"(Rizzardo, 2003). Improving the ow of material through new ideal system
layoutsatthe customer's requiredrate would reducewaste in material movement andinventory.
1.3.2 Thereis always roomfor Improvement
Afundamental principie of lean manufacturing
isdemand-basedflow manufacturing. In this type
of production setting, inventory is only pulled
througheachproduction center when it is needed
to meet a customer's order. The benefits of this
goalinelude:
Decreasedcyeletime
Lessinventory
Increasedproductlvlty
Increasedcapital equipment utilization
1.3.1 Designasimple manufacturing system
The following steps should be implemented in order to create the ideal lean
manufacturlngsystem:
1. Deslgnasimple manufacturing system
2. Recognizethat there isalwaysroomfor improvement
3. Continuouslyimprove the leanmanufacturing systemdesign
4. Measure
1.3 Stepsto achieveleansystems
doesnot addanyvalueto the product or service.Thereare seventypes of waste.
Reduce time: Reducingthe time it takes to finish an activity from start to finish is one of
the most effective waysto eliminate waste and lower costs.
Reduce total costs: To minimize cost, a company must produce only to customer demando
Overproduction increasesacompany's inventory costsdue to storage needs.
1
TECHNICAL ENGLlSH 3 2011 USAC
4
Reducedleadtime, wait time andcycletime
Liberated capital
Increasedprofit margins
Increasedproductivity
Improved product quality
J ustin time, affordable, streamlined, cost-efficient prccesses, products andservices
Improved on-time shipments
Customer satisfaction andloyalty
Employeeretention
Leanmanufacturing involves somereal positive, productive changesin businessesthat will havea
measurable impact inthe bottom line. Benefits of leanproduction could nclude:
Minimizing inventory at andthrough al!stagesof production
Eliminating waste
Reducingwait times, queues
Shortening product cyeletimes from raw materials to finished goods
To keepthings really simple, lean manufacturing hasa basepremise andoverall goal litoget more
done with less" andthis is effectively done, by:
A set of performance metrics which is considered to fit well in a Leanenvironment is overal
equipment effectiveness, or OEE,which is a hierarchy of metrics which focus on how effectively a
manufacturing operation is utilized.
( 1.3.4, Measure
A continuous improvement mindset is essential to reachacompany's goals.Theterm "continuou
improvement" means incremental improvement of products, processes, or services over time, witl
the goal of reducing waste to improve workplace functionality, customer service, or produd
performance (Suzaki,1987).
~
1.3.3 Continuouslyimprove
I
TECHNICAL ENGLlSH 3 ' 2011 U\,
s
Improve quality
TPS
Continuously Improve
Reduce Time
Leanmanufacturing
Activities
Complete the next chart with the next definitions:
",,1 ... _ ..t - ....
http://www.youtube.com/watch ?v=cOQ-xaYiorO&feature=related "
http://www.youtube.com/watch ?v=SU01D-jTZcE&feature=related (
http://www.youtube.com/watch ?v=Q89qAbAAR3Q&feature=related I
http://www.youtube.com/watch ?v=ZdHGTCXcJ QU&feature=related
http://www.youtube.com/watch ?v=mKb84Gafall
Suggestedvideos:
- Andon
- SixSigma
-55
- Kanban
- J idoka
- Heijunka
J ustintime
Kaizen
PokaYoke
Investigatethe following terms related to lean manufacturing and give their definition:
( 1.2 ) Homework:
TECHNICAL ENGLlSH 3 . 2011 USAC
SUMMARY
BODY
HEADER
Example:
And in the summary you will write al! the steps that the process has, including time. Time~
the most important factor becausewe useit to calculate the processefficiency andproductivity.
In the body, you will drawthe diagramthat is required according the specifications of ead
type and of the process.
In the header you will indude all the relevant information sueh as: company name, analyst
date, process, area, pagenumber, type of diagram, etc.
Thediagrams are composed bythree parts:
Header
Body
Summary
GIntroduction
The processdiagrams areveryimportant in the manufacturing industry becausethey give US
clear perspective of the processeswith everystep, including materials, time, distance andothers. Thr.
helps the engineers to interpret andanalyzethe manufacturing process and make decisions that wU
improve the processwithout beingthere to watch how everything works.
oPROCESS DIAGRAMS
I
TECHNICAL ENGLlSH 3 2011 US:
7
CheckIf It's not too hot, Enjoyl
Add the marshmallows
Geta cup and serve
CheckIf the chocolate is ready
Stlr frequently and let the
chocolate melt and get the
desired conslstency
Takethe 0.30pounds of chocolate
out of the bagand put It Into the pot
In a pot put lllter of water, in a stove
With hlgh flre, let It bol!
)
Get some marshmallows
O.Smln
Date: Nov. 20"', 2010
Type of dlalram: operatlons
Pall 1of 1
Analyst: J ohn Hamilton
Area: kitchen
Comptlny n.me: J ohn's house
Pl'Ocess: maklngof hot chocolate
D
D
o
Symbol
Comblned: this Is an operation-inspection step and is used
whenin the processyou haveto checkthe products during
Anoperation.
Inspection: is when we check how the process is goingand also
thequality of the product during the manufacturing process.
Operation: is when the process has materials transformation,
or involvesany action or activity for the creation of products.
Descrlption
eOperations Diagram
Thisdiagramis a graphic representation of the operations and inspections in a production process. In
thisdiagramwe'lI inelude the following symbols:
TECHNICAL ENGLlSH 3 \ 2011 USAC
Combined: this is anoperation-inspection step andis used
when in the processyou haveto checkthe products during
Anoperation.
De/ay: this is usedwhen nothing is beingdone in the process,
It could bethe wait for other paralell processto finish before
Adding the product to the asembly line.
Inspection: iswhen we checkhowthe prccess is goingandalso
the quality of the product during the manufacturing process.
o
O
D
D
Operaton: is when the processhas materials transformation,
or involves anyaction or activity for the creation of products.
In this diagram we indude the storage, operation, inspection, combined, delays and transportatio
symbols.
Symbol Description
eImportant conslderatlons
Note that the time is givenin minutes; thls is astandardfor all the diagrams.
The diagramalways isgoingto be drawn from right to left, even if it hassmultaneous processesor not.
Thetime is placed inthe upper-Ieft corner of the svmbol,
A brief description of everystep of the processis written at the right sideof the symboJ .
When numbering the processremember that you haveto do it accordingto its function in the diagram,
and when you have a simultaneous processyou haveto write the number on the left flrst and then in
the right, asshown in the example.
eProcessFlowDlagrem
The process flow diagramis a graphic representation of the steps that follows a chronologic sequence
of activities in a processor procedure, identifying them with symbols according to its nature, and also inelude
all the considered important information that is neededfor analysis.This information could be distance, time
quantity, etc. This helps us discover and eliminate waste and delays, making the process more efficient an
increasethe productivity inthe manufacturing industry.
11.4 8 Totals
Desaiptlon Symbol
'ofsteps nme
Operation
O
6 10.5
Inspection
O
1 0.4
Combined
e
1 0.5
Summary
!
TECHNICAL ENGLlSH 3 ' 2011 US
9
8Impcrtantconsiderations
Timeisgiveninminutes; this is a standard for al!the diagrams.
Thediagramisdrawn in aplanview of the manufacturing plant.
Thetimeis placedinthe upper-Ieft corner of the svrnbol.
Thedistanceiswrltten in meters andthe lower-Ieft corner of the symbol.
Abriefdescriptionof everystep of the processis written at the right sideof the svmbol,
Whennumberingthe processremember that you haveto do it accordingto its function in the diagram
andthesequenceinthe process.
Rememberto always draw the symbols in a 1 cm2 area. This is a standard for all the diagrams that
you'regoingto draw.
6ProcessTrave! Dlagram
Thisdiagramuses the same symbolism as the process flow and also the same structure, the only
differenceisthat wedrawthe diagramin a planview of the manufacturing plant.
8Important considerations
Timeis given in minutes; this is a standard for all the diagrams.
The diagram always is going to be drawn from right to left, even if it has simultaneous
processesor noto
Thetime is placed in the upper-Ieft comer of the symbol.
Thedistance is written meters and in the lower-Ieft corner of the symbol.
Abrief description of every step of the process is written at the right side of the symbol.
When numbering the process remember that you have to do it according to its function in the
diagram, and when you have a simultaneous process you have to write the number on the left
first andthen in the right, as shown in the example.
As the operations diagram, it has the same parts: header, body and summary, and it's
importantto ineludein the summary the time and distance that you have in the diagram.
v
Storage: this is used at the beginning of the process when the
Materials aretaken from the raw materials storage and at the end
Ofit in the finished product storage.
Transportation: is when the product is moved more than
1.5metersto the next step. This is because the human body
Canmovesomething from one side to other between Oand
1.5mandits irrelevant according to standars.
TECHNICAL ENGLlSH 3 :!O 11USAC
1 0
21 Totals
Descrlptlon Symbol #ofsteps Time Distante
Operation
O
9
Inspection
O
2
Combined
e
2
Transportatlon
e>
4
Oelay
D
3
Storage
\1
1
Summary
COUNTER
FINISHED
PROOUCT
STORAGE
PRODUCTION SHELF
BOTTLING ANO
PACKAGING
OFFICE
RAW MATERIALS
STORAGE
BACK ENTRANCE
Analyst: J ohn Hamilton
Area: manufacturing plant
Date: Nov 20111, 2010
Type of dlagram: process travel
Page 10fl
Company name: Industry S.A.
Process: production of ketchup
Example: (For space reasons, this diagram doesn't inelude the time and distance)
11
..
~UIJ llC:;t. I '.lOdl .....~ :'.1
.
IIOPE
PET
iiii
Accordingto the pieture below, determine what symbol eaeh operation needs:
Activities:
http://www.youtube.com/watch ?v=TI-dSckvwOQ
http://www.youtube.com/watch ?v=aSsNltVp9cA&feature=related
http://www.youtube.com/watch ?v=9YSAuwfOnXE
http://www.youtube.com/watch7v=3K3-stVKOIM
Withthegivenvideos, drawthe operations diagram, the processflow diagramandthe operations
travel diagram.
lo makethe operations diagram, usethe following link
http://www.youtube.com/watch ?v=gneZc_hafOE
lo makethe processflow diagramandthe processtravel diagram, usethe following link
http://www.youtube.com/watch '?v=OkHFNnOK3Bg
2.5 Homework
TECHNICAL ENGLlSH 3 2011 USAC
Description Symbol No. of steps Time Desc.ription2 Symbol No. of steps2 TIme2
Transfer to the Store (forklift)
Waiting to be transported
Sawdust andTables.
Assembly and Comprobation
Waiting to be processed
Transfer to the assemblyarea
(forklift)
Sawdust
Waiting to be transported
Storage
Cut and Comprobation
Sawdust 0.38%
Devastation and Comprobatlon
Waiting to be processed
Waiting to be processed
Transfer to the assembly area
(forklift)
Walting to betransported
Sawdust 0.32%
Cut and Comprobatlon
Walting to be processed
Transfer to the pendulum
(forklift)
Waiting to be processed
Sawdust6%
Sawingand Comprobation
Transfer to the pendulum
(forklift)
Crossstorage Tables storage
Complete the summary table for the diagram below:
TECHNICAL ENGLlSH 3 2011 U
13
eQualityAssurance
Qualityassurancefocuses on theability of aprocessto produceor deliver aquality product or
service. Thismethod differs from quality contrel in that it looks at theentire process, not just the final
product.Qualitycontrol ls designedto detect problems with a product or service; quality assurance
attemptsto headoff problems at the passby tweaking a production process until it can produce a
qualityproducto
After an organization decides on a definition of quality, you need
standardsagainstwhich to measureyour quality. Thereason is because
manystandardsare driven by the desireto safeguard and well-being of
thepeoplewho usethe products or servicescompanies provide. Quality
standardsarealsocritical in support of international trade.
GQualitycontrol concepts
Costumer based: Quality is meet customer expectations.
Statistical based: The less variation you have, the higher the
qualityof your product or service.
For most people, quality is associatedwith the idea of a product or
servicethat is well done, looks good anddoes its job well. We think of a quality product as one that
lasts,holdsupwell under use, anddoesn't require constant repair. A quality product or serviceshould
meetahighstandardin manyareas, suchasform, features, fit andfinish, reliability andusability.
r.jUII".l '1; E
o" \....
@Introduction
Qualitycontrol is acritical concept in everyindustry and profession.
~ t\obaUzation continues andthe world becomesmaller, making it possible
forconsumers to pickandchoosefrom the best products worldwide, the
survival of yourjob andof your companydependson your ability to produce
'-
aquality product or service. In this chapter, we define the term "quality",
andweintroducesomeimportant quality control concepts and methods.
G QUALITY CONTROL
1 EO",N\Cl\l ENGl\S\-\ '3 ~ 2011 USIl.C
Statistics helps you to determine which processes or parts of
processesare causingyour company the most problems (by using
the 80/20 rule - 80 percent of your problems are caused by 20
percent of what you do).
You can use statistics for sampling sothat you don't have to test
100percent of the items you make.
Statistics can help you spot relationships between the values you
measure- even if the relationships aren't obvious. -1 heyalso allow
you to identify small variations in your process that canlead to big
problems if you don't correct them.
Aithough, much.ofstatisticsallowsyouto lookbackonlyetwas happenedinthe pastoStatisticalP
Control (SPC) allowsyouto identifyproblemsbeforetheycannegativelyimpactthequalityof yourproduct
service.ThebasicideabehindSPCisthat if youcanspotachangein a processbeforeit getsto the point
makingbadproducts,youcanfixtheprocessbeforebadproductshitst~eshelves.
GEvaluatlngthe qualtty
The most common way to analyze the data you collect s to use
statistics. Statistics servemany purposes within quality control:
Employee training is critical to ensure that everyone involved in your process measures tht
samespecifications in the sameway. You alsoneed to collect data in a usableformat sothat you cal
analyze it to determine the effectiveness of your quallty process. The effectiveness of your qualiq
process is directly related to the quality of your data collection andanalysisprocess. If you don't hav!
a gooddata, you can't makegood decisions.
The old manager saving: "You can't manage w ha
you can measure" rings especiallytrue in quality control
A good measurement systemhelps you to know wher
you've been and where you are going. Costumer
typically require that you measure certain attributes e
your product or service against their specifications. Se
working in quality control means that you have a
determine what to measure, howto measure it andw her
to measureit.
@Measuring the quality
TECHNICAL ENGLlSH 3 2011 U S-
15
.-- Tito 99" o' """"""
..._ D..I , " 'n , . '. 1 "n !!" V tJ 'Q"I" . 1 1
,,,lIclllhm 91 ... "" prlllCllpl . .
Un ll.'.'Alllllln t flow J I''''_ _
~ 41 1 1 ". "")'9P"I'. , 1 ha
flllln " .lI o" l fo, '" aflllll"
,t. ,.
U51NG I foil VAl lJ t Sr RE.AMMAPPI NG Tn OL
Peoplethin k in images, n ot in words, so
givln gthemapicture of howsomethin g is don e
is often better than tellin g them about a
process. After all, the quote is " Showme the
mon ey!"n ot" Tell meabout the mon eyl"
@Lean Techn iques
eValueStreamMappin g
ValueStreamMappin g visually describes a
production process in order to help workers
locatewastewithin it. Waste is an yactivity that
doesn 'taddvalue for the customer. Typically,
elimin atin gwastein volvesreducin gthe amoun t of in ven tory sittin g aroun d an dshorten in g the time it
takestodeliveraproduct orserviceto the customer upon its order.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Youcan apply the lean techn iques in the followin g section s to all types of processes an d
en viron men tsran gin g from offices, to hospitals, to factories. I n most cases applvn g lean con cepts
doesn 'trequirean in creasein capital costs- it simply reassign speople to more productive purposes
an dofcourse,lean processesare cheaperto operate.
Most compan yprocessesare wasteful in terms of time an d materials, which often results in
poorer quality to the costumer- acon eern of all busin esses. lean focuses in customer satisfaction
an dcostreduction .Propon en tsof the techn ique beHevethat everystep in aprocessls an opportun itv
to makeamistake- to create aquality problem, in other words. The fewer steps you have in a
process, the fewer chan cesfor error you create an d the better the quality in your fin al product or
service.
I n troducin g Lean Processes
lean processesare the latest diet craze in the world of quality con trol. Lean is aquality con trol
techn iqueyoucan useto iden tify an delimin ate the flab in your compan y's processes.The " flab" is all
thedeadweightcarriedbyaprocesswithout addin g an yvalue.
,
TECHNI CAL ENGUSH 3 2011 USAC
l E
No one knows a process like the workers who touch it every day. They know how the worl
should flow, they can identify obstacles that slow everyone down, andthey deal with problems tha
never seemto go away.
A RapidImprovement Event (RIE)is an intensive process-activity improvement, where over
. few days acompany's workers bone up on leantechniques andrebuild their processesto incorporan
its principies. The workers take apart their work areas, rearrange items and reassemblespacesf O I
more effcient work. The improvements are immediate, and the workers have ownership of thl
processandfine motivated to further refine it.
eRapidimprovement events
Removing the clutter from a process eliminates
hidden Inventores, frees f100r space for productive
use, improves the flow of materials through the
workplace, reduces walk time, and shakes out
unnecessary items for reuse elsewhere or landfill
designation.
Seiri (organization)
Seiton(neatness)
Seiso(cleaning)
Seiketsu(standardization)
Shitsuke(discipline)
TheSSmethod is an essential tool for any quality initiative that seeksto clear up the flow o
work. TheSSdescribefive J apaneseattributes required for acleanwork place:
elheSSmethod
Work areasevolve alongwith the processesthey support. As anorganization implements ne~
actions andtools, you must find aplacefor them "somewhere". Overtime, clutter canslowly buildal
piles of excessmaterials or tools grow andgradually gumupthe smooth flow of work.
TECHNICAl ENGlISH 3 I 2011 US;
,
17
http://www .youtube.comfwatch ?v=U7Z33tljMTQ
http://www.youtube.com/watch ?v=ldhC4ziAhgY
Suggestedvideos
Investigateandmake asummaryof the following topies:
Total Quality Management (TQM)
SixSigma
Toyota Production System (TPS)
Homework
Youdon't want to eliminate sothoroughly that you causeshortages. One method you canuse
tofixthe problem of excess materials without causing shortages is Kanban. Kanban s a materials
systemcontrolled by the customer. When the customer buys an item, action cascades back up the
productionlineto makeone moreof that item.
eLeanmaterial. and Kanban
A company's materials are essential for the organization to work well, but they alsotied up a
largepart of a company's capital. And while the company does its business year in and year out, its
materialsare, stolen, damaged, rotting, corroding, and losingvalue in manyother ways.
A key part of the lean approach is to minimize the amount of materials (both incoming and
finishedgoods) you have sitting around in your facility. Excess materials hide problems with
purchasing,work scheduling, scraprates, and so on. Eliminating this excess materials provides an
immediatefinancial benefit to your company- if you eliminate correctly.
TECHNICAL ENGLlSH3 2011 USAC
I
1
.7. .. ~ _ - _
Lean material and Kanban .
. .
.. .." . _ . ... l O .. . .
,>
Value stream Mapping -
Compl etewith the description of each l eantechnique:
Writeineachscrewadifferent description about QualityControl:
Activities:
TECHNICAL ENGLl SH 3 . 2011 US
,
19
Completethe chart with the5s technique:
#o "'-, I,.,I,'<.>thr .." "';oiI aO:O:'1A t.J c./ ~:"'''''.1l''! 'CC4" I,u. b
.... 1.... k1 ,lbll _ ... -,". " "I. ,J , ..... :..n.;u.1~t\~), ~. tlr._I -'
~u~'",....,._w ." ~"'-" 1-1*'$ ... hMi".._
~tr;J OS,J "" -:.,'" ..... ~ .,.. ~.v(..(_"_
E)0il
Companies drill for oil on land or in the ocean and store it
in large barreis or underground tanks. People turn oil into many
products, induding plastics. Your ballpoint pen, your nylon
backpack, and even your fleece jacket are all made from oll, Sorne
homes burn oil for heat and sorne power plants burn otl too. In
many countries, however, oll's main useis for transportation. OiJ is
eToday's energysources =fossil fuels
eCoal
People mine for coal, a hard, black, rock, throughout the
world. Power plants use coal to generate electricity by grinding it
into a powder that is burned. The burned powder heats water to
create steam. The power of the steamturns turbines. The splnning
motion of the turbines generates electricity. A network of wires
called power grid, bring this electricity to houses and other
buildings.
Most everything inthe world needs energyto work. Think about the energyyouuseeachday: the
lights youturn on, the busor caryoutake to school, the computer youusefor homework, the television you
watchbefore bed. Evenwhile yousleep, energy runs your furnace heating your houseandthe refrigerator
keepingfood from spoiling. It evenrunsthe alarmdock that wakes youup in the morning. Nowthink about
how manypeople live on the Earth.Withapopulation of more than 6billion, the world usesa lot of energy.
Youneed energyto start your day.Your breakfast isthe fuel your body needsto work. What wouldy
do if youran out of your favorite cereal?Youcould buyanother box. Butwhat if the storewas all out, too?
What if it wasn't getting anymore deliveries? What would youdo then? The answer seemssimple; you'd ha
to find another food for breakfast.Theworld faces a similar problem; our fuel resourcesare running low and
could run out in your lifetime.
@Introcluction
ALTERNATIVE ENERGY

TECHNICAL ENGlISH 3 . 2011 L

21
Finally, burning fossil fuels harms Earth. Coal, ol, and natural gas create a lot of air pollution. The
burningof fossil fuels releasesharmful emissions that causeasthma and other health problems. This pollution
alsoleadsto acidrain andsnow. Many scientist andcitizens are eoneerned about the carbon dloxlde released
byburningfossil fuels. Carbondioxide belongsto agroup of gasesknown as greenhouse gases. As these gases
colleetin the atmosphere, they aet like the glass walls of a greenhouse, trap~ing warm air close to Earth's
surfaee. Thiswarming is natural, and long ago it made the planet's environment mild enough to support life.
However,when human activites pump larger-than-normal amounts of earbon dioxide into the atmosphere,
moreheatis trapped, andtemperatures cangrow unnaturally hgh. As a result, there canbe major effeets on
weatherthat may bedevastatngto the environment andall the people on Earth.
Thesecondfaet isthat the fossil fuels cost a lot of
money. Countries buy fossil fuels from eaeh other.
Becausethe supply is low, they can raise their prices. If
countriesgoto war or havea disagreement, they may nct
wantto buy fuel from each other. No one will get what
theyneed.
GTheproblems 01theuseof thefossll fuels
Fossilfuels have been a useful source of energy, but we need to rethink how mueh we depend on
them. We need to consider three maln facts. First, fossil fuel supplies are low. We use so much energy that
somedaywe'lI useup all of Earth's fossll fuels. At the rate we use now fossil fuels, scientists' estimate that the
world'sreservewilllast 40 to 70 more years. What will happen after all of the oil, coal, and natural gas have
runout? Howwill we traveJ from place to place? Howwill
welightour homes? HowY!II we communicate with eaeh
other?
Companiesdril! for natural gas the same way they do for oil. Natural gas is highly f1ammable. Gas
stovescook food with a lower flame. In the United States, and probably other eountries, the house's heating
systemandwater heater mayusenatural gas.Natural gasis alsousedin power plants to create electrieity.
eNatural gas
madeintogasolinefor cars,diesel fuel for trucks, andjet fuel for airplanes.
I
TECHNICALENGLlSH3 2011 USAC
Covbll .~ .........: _ ..-__ ..... ,r
The cells generate electrical power when the sun is shining. But
what happens at night or when the sun is covered by clouds? Batteries
store the electrlcity: becausesolar panels absorb light, not heat, they still
create electricity during acold winter. As long as the sun is shining, PVcells
are at work.
Yearsago scientists developed solar cells, alsocalled photovoltaic cells or PVcells, which canturn
light directly into electricity. Thesesrnall, flat devices made of silicon come in avariety of sizes.Youmay
seen PVcells in acalculator. Sornebillboards and streetlights usePVcells to operate. Most cells are4
4 inches (10 centimeters by 10centimeters) and grouped together in panels on the roofs buildlngs. The
panel absorbs the sun's light and transforms it into electric current. The electricity can then run
machines, andappliances ;nthe buildings. The more ?Vcells, the more electricity panelscancreate.
eHcw sola, ceUenergy wo,lcs
Put on sunglasses,rub in sunscreen, and hit the beach. It's time to
soak up some rays! The sun cangive you a great tan or make you sweat
playing Frisbee. The sun's light and heat canalso help us solve our energy
problems. You have probably noticed wires running from your home to
poles on the street. These wires connect you to the power grid of your
community. Home's that usesolar power, don't needas much energyfrom
the grid. There are two types of solar power: solar cell energy and solar
thermal energy.
GSola, energy
(';;\ The solutions
~hat canwe do about our energy problems? Insteadof relying on fossil fuels, we needto examine
"green" alternatives. Green energy is renewable - it is constantly being replaced and won't run out.
forces, such as wind, water, and sunlight are green energy sources. It's not easyto switch to green e
however, we rely on fossil fuels every day. People would need to spend huge amounts of money to
from one kind of fuel to another. We need to take action, but first, we need to understand our
alternatives, then we canmakethe best energychoicesto preserveour planet.
TECHNICAL ENGLlSH 3 . 2011 u
25
Activities
Writein eachsquareand explainsomeenergysources: .
http://www.youtube.com/watch ?v=oIUSfFmOeSc
http://www.youtube.com/watch ?v=q_fvb02VXjc&feature=related
http://www.youtube.com/watch ?v=T1HmY_lmHAg&feature=channel
http://www.youtube.com/watch ?v=KIGOxk93J -E&featu re=channel
http://www.youtube.com/watch ?v=oJ AbATJ Cugs&feature=fvw
Suggested videos:
Investigate at least 15technical words from this chapter that you previously did not know and
write the translation anddefinition of each
Investigate about the following topies: magma, and mantle
Watch the suggestedvideos. Then, answerthis question: What couldyou do help to introduce
people to living a "green" life? What aresomewaysto changetheir way ofthinking and living?
4.8 Homework
TECHNICAL ENGLlSH 3 2011 USAC
2
Conduction: it is the flow of heat that occurs, either due to the exchange energy from one
molecule to another without appreciable motion of the molecules or due to the motion of free
electrons if they are presentoConduction occurs on the molecular scale, molecules with a
relative higher energy imparting energy to adjacent molecules at lower energy levels. For
example, the heat flow through the brlck wall of a furnace or the metal wall of a heat
exchangertube occurs byconduction.
Convectlon: it is the transfer of heat between relatively hot and cold portions of a fluid by
mixing (convection occurs through actual physical movement of warmer portions of fluid
towards cooler portions of the samematerial). Convection is thus restricted to the flow of heat
in fluids. If the fluid motion is caused by differences in density resulting from temperatur
difference in afluid, the heat transfer is saidto be free or natural convection. If the fluid motio
is artificially created by means of an external agency like pump, blower or agita~or, the hea
There are three distinct modes of heat transfer from a source to a recever: conduction, convection and
radiaton.
5.2 Modes of heat transfer
The major difference between thermodynamics and heat transfer is that the former is concerned with
the relation between heat and other forms of energy, whereas the later deals with the analysis of the rate 01
heat transfer. Thermodynamics deals with systems In equilibrlum, so it can't be used to predict how fast a
change will take place since the system is not in equillbrium in a process but it may be used to predlct the
amount of energy required to changethe systemfrom one equilibrium state to another. Consider the coollng
of a hot steel bar that is placed in ajar of water. Thermodynamics may be usedto predict the final equllibrlum
temperature of the steel bar-water system but will not tell us how long it will take to reach the equilibrium
condition or what the temperature of the bar will be after a certain time period before the attalnment 01
equilibrium condition whereas heat transfer may beused to predict the temperature of both bar and water as
afunction of time.
Heat transfer isthe sciencethat dealswith the study of rates of exchangeof heat between hot and cold
bodies. The hot and cold bodies are calledthe souro: and the recelver respectively. Processheat transfer deals
with the rates of exchangeof heat as they occur in the heat transfer equipment of engineering and chemical
processes. In all suchcases,the temperature difference between a source and a receiver acts as a driving force
for heat transfer.
(5.1 Introduction
TECHNICAL ENGLlSH3 2011 U SA C
01 HEATTRANSFER
27
1. Fourier's law of heat conduction
2. Newton's law of cooling/Newton's law of heat flow between a solid surface and a fluid.
Thesubsidiary laws generally used are:
Thefundamentallaws used in heat transfer are:
1. Lawof conservation of mass
2. Newton's law of motion
3. Lawsof thermodynamics
The foundation of heat transfer rest on a number of the fundamental and subsidiary laws. A
fundamentallaw is the one which validity rests on the fact that it has not been proved to be wrong or
falsein the broad area of appfication of the subject under consideration. Therefore, these laws must
besatisfied in so\ving any prob\em. On tne other hand, a subsid\af'i \aw may be emp\f\ca\ in nature,
5.3 , Thelaws of heat transfer
In the case of an insulated steam pipe, heat flows by convection through the steam film on the
insideof the pipe, by conduction through the layer of scale and the metal wall of the pipe, and the
layerof the insulation, and finally by convection and radiation from the outside insulation to the
ambient/surrounding airo Hence, in this case, heat transfer involves all the three modes of transfer.
Thisis also true with almost all heat transfer applications in the process industries. In a large of
practical cases, one of the modes could be dominant, whereas in severaI cases it is required to deal
with more than one mode of heat transfer, owing to significant impact of these modes on the overall
heattransfer rates.
In many of the applications of heat transfer in chemical engineering, heat will be transferred
bycombination of two or three of the basic mechanisms/modes of heat transfer. Consider a double
pipeheat exchanger in which a hot fluid flows through the inside pipe and a cold fluid flows through
theannular space. In this case, heat will flow by combination of convection and conduction from the
hotfluid to the cold fluid. Here heat flows by conduction through the metal wall of the inner pipe and
depositson both sides of the inner pipe, and by convection through the fluid films.
TECHNICAl ENGlISH 3 2011 USAC
transfer is termed asforced convection. The heating of water in acooking panis an example of
heat transfer mainly byconvection.
Radiatlon: it refers to the transport of energy through space by electromagnetic waves. The
transfer of heat from the sunto the earth is the most important example of heat transfer by
radiation.
21
I ~" ~ - ~1 = ~2 +~~/dt I
: 6 t:::.:_~ +dh/dt ;
I f mi >m2water gets accumulated in the tank and if mi <m2water gets depleted. for steady state operation
when accumulation is constant or nil, the equation reduces to:
[ : : ~ : p ~ ~ = ; O (
Rate at which water enters the tank = rate at which water leaves the tank +rate ot occumuiauon o/ water
the tank
Consider a water tank containing some water initially as shown in fig. 1.1 Water enters the tank at
rate of mi kg/h and leaves the tank at arate of m2kg/h and accumulates at arate of dm/dt. Then accordingj
the lawof conservation of mass,
Examples:
Input = output +accumulation ordisappearonce
Thus for anyunit operation or unit process:
Fundamentallaws
eLawof conservation of mass
I t states that the total mass o/ various components involving during o unit operaton or unit prOCeJ
remains constant or simply the total mass o/ the moterials toking part in any process ls constant. Conservatio
of mass requires that the materials entering any process must either accumulate and/or leave the preces
There canbe neither loss nor gain.
3. Lawsof thermal radiation.
4. Equationof state
TECHNI CAL ENGLlSH 3 . 2011 U S
1
23
A te , - . . . . ,."lo'1II - . 10~ ~~. " . . . . . . . . .
, ~. . __- . , . , . J . . ~. , . . . _ . _~tU1
Windcan be powerfui, as with a destructive hurricane, but its power can
alsobe used for good. Sailors use the wind to keep their sailboats moving.
Throughouthistory people have usedwindmills to harnessthe wind's energyfor
grindinggrain or pumping well water. Today people use wlnd turblnes to
generateelectricity.
Wind ls moving airoThe motion is causedbychangesIn air temperature. Warm air Is IIght, and cold air
isheavy.Whenthe land beats up during the day, it warms the air aboye it. This warmair rlses higher in the sky;
whilecoldair moves down to fill the spaceleft bythe warm alr. Thls movement of air creates wind.
8Wlnd Ene,BY
Thermal energy can also create electricity. In a solar power plant, the sun heats a IIquid until it boils.
Thenthe steamcreated from this boiling liquid runsaturbine to generate electricity. In order for the llquids to
boil,thesepower plants usemlrror to tocus the sun's heat and increase its strength. Somemirrors are curved
andshapedlike a saucer. Others are shaped like a trough or placed in a line. Some new solar energy plants
haveapower tower. Thousands of mirrors surround the tower andfocus the sun's heatto the topo
. . . . . . . . . ". , , . . . . . . . . . NI y pi ~..-.
. ~, ' ' 1, . . , . 1". """', . ,, . . . _,
Solar thermal energy uses heat instead of light. People can place
thermalpanels on their roofs to absorb the sun's heat. Tublng filled with
waterruns under the panels. The sun warms the water. Thls water can
thenbeusedto make acup of cocea, fill a swimming pool, or run through
ahome'sheating system.
eHow sola, thermal energy wo,ks
Your family can install solar panels on your home, even though you are connected to the power grid. At
times, the panels may even generate more power than your home needs. The power company then buys any
extra power you create and puts It back Into the grid for someone else to use. So by uslng solar panels you
couldhelp your whole community rely more on a green energy source.
TECHNICAL ENGLlSH 3 ' 2011 USAC
2 4
Water sometirnes eollects in the rocks underground and heats up
If there is a vent leadingfrom this deep rock to the suace, superheata
water shoots upward. Earth's crust isthicker in sorneareasthan others.
'1 5 W ' I.t. " " " ') 1 . . . . ,.,.,,l'1 < li4
......... .....Il'.~""" ...... !IN,~.a.."'''' ,. w. . . . . . . .,llu....1 i1 :rt,ll+
layers. At the center, Earthhasasolid coreoAround this eore is an area of hot, tiquid rockealledmagma. AboVl
the magma is a layer of solid rock and magmacalledthe mantle. The temperature of the rnantle can beveq
_ ...... ,..... _ high - frorn 2,5 20to 5 ,400 degrees Fahrenheit (1 ,382to 2,982 degree
Celsius)depending on how deep you go. The surfaeeof Earth, the crust
sits on the mantle.
Old faithful, Yellowstone National Park's most farnous geyser,
erupts with thousands of gallons of water andsteam every hour to hour
and a half. This popular Wyoming tourist spot is the horne to more than
60 percent of the world's geysers. In just one square rnile (2.6 square
kilometers), youcanseemore than a 1 5 0of them.
Sornepeople think of Earthas a solid ball of rock, but thas many
\"_V..lI"Af' ~N7 " '~'K" r . . u,1 'I t l'....
'01 . ';, . . . . . ,. . , . . . . . . r . ;. ' 01 p. . . . :_,-. : C'I V'!o-
owned by "wind farrners" who sell the electricity to power companies. Willl
turbines work best where wind blows strongest. Wind is usually stronge
the higher you go. That's why turbines are often mounted on tall towers o
placedon the top of hills. Sornetowers stand between 1 00and 25 0 feet (31
and 76 meters) high. Shorelines andwide-open prairies are alsogood place
for towers. Turbines don't work well in location of too many rnountains
forests, or buildings, which block the wind's flow. Sornepeople place smal
turbines on their roofs and position them in away to catchthe rnost wind.
' ,. I I 1 ooj _c __
(,. . ,. . . , (1 -. . . . " ,,,. . ,,. . ,,,,,,,,,
eGeot her mal ene'l'l
l......... t " ',. . . ~ I ,,:. . '" I ~ (:(" 1 1 ' .,.,.1 "" ~ ...
"'" ,....,_"k:,."j b (,:1"1"\ WIffl'IJ n. _iI' ~n. c . A . " " "
To increase the amount of power, turbines are often grouped in wind
farms. Most wind farms aren't owned by electric power companies. They are
eHowwind power wor ks
A wind turbine has what looks like an airplane propeller mounted very
high in a tower. The bJ adesof the turbine catch the wind and spin. The blades
spin a shaft that is connected to an electrical generator. Wires connect the
generator to the power gridto bring electricity to buildings inthe area.
29
J
Foraone-dimensional flow in tne x-direction, we have:
-
WhereM =mu; m is the massflow rate of fluid and u isthe linear velocity of the fluid.
Forthe volume control show in Fig. 1.2 assuming flow to be steady and unidirectional in the X-direction,
accordingto Newton's second lawof motion, the sumof all forces actingon the fluid in the x-direction is equal
tothe increasein the time rate of changeof momentum of the tlowing fluid. For example, sumof all torces
actingin the x-direction equals the difference between the momentums leaving with the fluid per unit time
andthat brought in per unit time bythe fluid.
f rF=1/gc(M2-M~
WhereFisthe resultant of all forces acting onthe body, mls massandu isvelocity.
F=k d/dt (mu)
It states that the resultant 01 all forces acting on a bady 01 mass NmNis praportional to the time tate 01
momentum change 01 the body in the direction 01resultant force.
5.4.2 Newton'ssecondlaw of mation
Thisisthe equation of continuity.
Plu1A1 = PZUA~~
puA = constant
------
let ul and u2 be the velocities of the fluid at entrance and exit. Let p1 and p2 be the densities of the
fluidatentrance and exit. Assumedensity ina singlecross-section is constant and u1 is constant across areaAl
andu2is constant across area A2. For steady-state conditions, the rate of mass entering the control volume
equalsthat leaving.
u~p.
- -.
Considera stream tube (control volume) as shown in the figure 1.2. Assumethat a fluid enters at a
pointwheretheareaof cross-sectionof the tube is Al and leaveswhere the areaof cross-sectionis A2
TECHNICAL ENGLlSH 3 2011 USAC
3
1
1
[ dU=dQ-dW
[
. 'dU _ dQ dW
dt - Tt- dt
Takingderivatlves from respect to time,
The equatlon applles to the processesinvolving finite changesinthe system. Fordlfferentlal changes,
thls equation iswritten as:
This isthe mathematical expression/statement of the flrst lawof thermodynamics. Inwords, the
equation states that the total energy change of a system is equal to the heat added to the systems minus the
work done by the system.
- - - ,
J
I Q=I1U+W
LL1U=Q-W
Heat absorbed by system =increase in internal energy +work done by the system
Let the Initial state of a systembeA. let the quantlty of heat Q be absorbed by the system. The result
absorptlon of heat is both to increasethe internal energy andalsoto produce somemechanical work.
It states that energy can neither be creoted nor destroyed during a process, although the conversion
energy from one form into another is possible. The lawcanalso be stated in the alternative way as - the
energy of an Isoloted system remains constant. When systemgains or lossesenergy, It must be exactly equal
the loss or galn of energy by the surroundlngs. Hence, the first law of thermodynamics is concerned with
conservation of energy.
(5.4.3 Flrst law of thermodynamics
Where Pl and P2are pressures at entrance andexit; Al and A2 are cross- sectionarea at entrance andexit,
the net force of wall channel on fluid and Fgis the component of force of gravity (for flow in upward dlrectlort
From the last equation we can say that the rate of increase of energy of the system is equal to tbe
difference between the rate at which heat enters the system and the rate at which the system does work on
surroundings.
---
r
3.-Explain First Lawof Thermodynamics:
~ ~_ ._ 'a ~. P J _ _ '.
1
r
\
2.-Explain Newton's second law of motion:
1
'"=--.,-
1 .- What is radiation?
Answerthe following questions:
Activities
http://www.youtube.com/watch ?v=77R4arwD8G8&feature=related
http://www.youtube.com/watch ?v=SpG-tkbQgMo&feature=related
http://www.youtube.com/watch ?v=SOTurHQp _AE&feature=related
http://www.youtube.com/watch ?v=8jeHd3ZbsFg
http://www.youtube.com/watch ?v=wz6wzOtv6rs
http://www.youtube.com/watch ?v=OSSlxXFGpKk&feature=related . )
~ ...... ~ 1'~''''''''''''lI*;:~
Suggestedvideos:
Investigateabout the subsidiarylaws of heat transfer.
Watchthe following videos
5.5 Homework
TECHNICAL ENGLlSH 3 I 201 1 USAC
3
Solar cells generate most of their electricity from direct sunlight. They can also generate electricity
cloudv days- and somesystemscanevengenerate very small amount of electricity on bright moonlght ng
When a photon hit the solar cell, it cando one of three things: it can beabsorbed bythe cell, be reflecl
of the cell, or pass straight through the cell. If a photon is absorbed by the slllcon, this causes some of 1
electrons to jump from one layer to another. Anelectrical circuit is madeasthe electrons move frorn one la
to another, creating an electrical current. The more photons (the more intensity of Iight) that are absorbed
the solar cell, the greater the current generated.
To create this effect, two layers of a sem-conductng material haveto becombned. One layer hasto h i
a depleted number of electrons. When exposedto sunlght, sorneof the photons are absorbed bythe mate
which excites, causing some of them to jump trom one layer to the other. As the electrons move from (
layer to another, a small electrical current is generated. The semi-conducting material usedto build a solarI
is slicon. Very thin wafers of silicon are cut and polished. Some of these wafers are doped to contamm
them, thereby creating an electron imbalance inthese wafers. The wafers arethen aligned together to mak
solar cell, Conductive metal strips areattached to the cells to take the electrical current.
6Th epri nci pi es of solar electri clty
A solar panel generates electricity usingthe photovolto;c effect, aphenomenon discovered inthe early:
Century, when it was observedthat certain materials produced anelectric current when exposedto light.
Solar electricity is a wonderful concept - taklng power from the sun and using it to power electr
equipment is aterrific idea. No ongoing electricity bilis, no reliance on an electrical socket - "free" energv
doesn't harmthe planetl
Oirect\'i or \ndirect\'i, OUT sun provides a\\ tne power we need to exist and support alllife forms. The\
drives our climate andour weather. Without it, our world would be afrozen wasteland of ice-covered rock.
nuclear activity.
oSOLAR POWER
eIntroducti on
93 miliion miles from Earth, our Sunis 333,000 times the sizeof our planet. It has a diameter of 865,
miles, asurface temperature of 5,600Cand, acore temperature of 15,OOO,OOOC. It is a hugemass of cons
TECHNICALENGUSH3 2011

33
Withsolarpoweredbollers, thls isinsteadfuel!edbythe solarpower collectedthrough panelsonthe roof of your
home.
Solar BOllers:
Themainwaythat aconventional gas"comblnation boler" continuallywastesenergyisbyreplenishingstored
waterassoonasthevolumeor temperature decreases.
Fromwater
tank
To water
tank
Glass
Solar cover
Energy' \
BlaCk"\,
This helps out your central heating system, and
cutsyaur fuel bilis. However, with the basictype of
panel showninthe diagramyoumust drainthe water
outto stop the panelsfreezing in the winter. Sorne
manufacturers llave systems tnat do this
automatically. Solar water heating is easily
worthwhile in places like California and Australia,
where you get lots of sunshine. Mind you, as
technologyimprovesit's becomingworthwhile in the
U K .
Wnercheatfromthe Sunisusedto heatwater inglasspanelsonyour roof. Thismeansyoudon't needto useso
muehgasor electricity to heat your water at home. Water is pumped through pipes in the panel. The pipes are
paintedblack, so they get hatter when the Sunshines on them. The water is pumped in at the bottom so that
convectionhelpstheflow of hot water out of the topo .
Solar Water Heating:
Ina sunnyc1imate,you canget enough power to run a
lOOW light bulb fromjust onesquare meter of solar panel.
Thiswasoriginally developedin order to provide electricity
for satellites, but these days many of us own calculators
poweredbysolar cells. Peopleare increasinglyinstallingPV
panelsontheir roofs. Thiscoststhousandsof pounds, but jf
youhaveasouth-facingroof itcanhelpwith your electricity
bilisquitea bit, andthe govemment paysyou for anyextra
energyyou produce and feed back into the National Grid
(ealledthe "feed-intariff").
(reallycalled"photovoltaic", "Pv" or "photoelectric" cells)thatconvert light directly lnto electricity.
SolarCells
Individual solar cells typically only generate tiny amounts of electrical energy. To make useful amounts of
electricity,these cells are connectedtogether to makea solar module, otherwise known asa solar panel or, to
~mQt~",t~dse, a photovoltaic module.
TECHNICAL ENGLlSH3 2011 U SA C
3
Solar fumaces are basically huge "solar cookers". A solar cooker
can be used in hot countries to cook food. This one is in the UK,
making tea and coffee, although it does take a long time!
Use a huge array of mirrors to concentrate the Sun's energy into
a small space and produce very high temperatures. There's one
at Odeillo, in France, used for scientific experiments. It can
achieve temperatures up to 3,000 degrees Celsius.
Solar Furnaces:
The power collected through the solar tiles is used to fuel and therefore
heat a seprate water cylinder, thus saving energy throughout the course
of every day. Another smaller tank, still powered by gas, is provided with
most solar boiler installations as a backup.
I
TECHNICAL ENGLlSH3 2011 US,
35
The production of bioethanol from traditional means, or 1st
GenerationBiofuels is basedupon starch crops like corn and wheat
andfrom sugar crops like sugar cane and sugar beet. However, the
cultivationof alternative sugar crops like sweet sorghum opens up
newpossibilities in Europe, especallv in hotter and drier regions,
suchas Southern and Eastern Europe. Sweet sorghumrequires less
wateror nutrients and has a higher fermentable sugar content than
sugarcaneas well as a shorter growing period which means that in
sorneregions like inAfrica vou canget 2harvests ayear from the same
crop. In addition to thls, the development of lingo-cellulosic
technologyhasmeant that not only high energy content starch and
sugarcrops can be used but also woodv biomass or waste residues
frorn forestry. This development is seen as the 2nd Generation of
Biofuels.
Bloethanol Productlon:
In recent years the concept of the bio-refinery has emerged, whereby one integrates blomass
conversionprocesses and technology to produce a variety of products including fuels, power, chemicals
andfeedfor cattle. In this manner one cantake advantage of the natural differences in the chemical and
structural composition of the biomass feed stocks.
Bioethanolls seenasagood fuel alternative becausethe source crops canbegrown renewably and in most
cJ irnatesaround the world. In addition the use of bioethanol is generally C02 neutral. This is achieved
becausein the growing phase of the source crop, C02is absorbed by the plant andoxygen is released in
thesamevolumethat C02is produced in the combustion of the fuel. This creates anobvious advantage over
fossllfuels which only emit C02 as well as other poisonous emissions. In the 1970s, Brazil and the USA
startedmassproduction of bioethanol-grown from sugarcaneand corn respectively. Smaller scaleproduction
startedmorerecently inSpain, Franceand Swedenmostly from wheat andsugarbeet.
Bioethanol production
Inrecentyears, largely in responseto uncertain fuel supply and efforts to reduce carbon dioxide emissions,
bioethanol(alongwith biodiesel) has become one of the most promising biofuels today and is considered as
theonly feasible short to medium alternative to fossil transport fuels in Europeandin the wider world.
I
TECHNICAL ENGLlSH3 2011 USAC
36
Bioethanol has a number of advantages over conventional fuels. It comes from a renewable resource i.e.
crops and not from a finite resource and the crops it derives from cangrow well (Iike cereals, sugar beet anc
maize). Another benefit over fossil fuels is the greenhousegasemissions. The road transport network accounts
for 22%of all greenhouse gas emissions and through the use of bioethanol, sorne of these ernisslons will be
reduced asthe fuel crops absorb the C02they emit through growing. Also, blending bicethanol with petral wil
help extend the life of the diminishing oll supplies andensuregreater fuel security, avodingheavyreliance on
ol producing nations.
Benefits
Ethanol or ethyl alcohol (C2HsOH)is a clear colourless liquid, it is biodegradable, low in toxicity and cause:
little environmental pollution jf spilt. Ethanol burns to produce carbon dioxide and water, is a high octane fue
and has replaced lead as an octane enhancer in petral. By blending ethanol with gasoline we can als(
oxygenate the fuel mixture so it burns more completely and reduces polluting emissions. Ethanol fuel blend:
are widely sold in the United States. The most common blend is 10%ethanol and 90%petral (El0). VehielE
engines require no modifications to run on fl0 and vehicJ ewarranties are unaffected also. Only flexible fue
vehieles canrun on up to 85%ethanol and 15%petral blends (E8s;.
The main sources of sugar required to produce ethanol come from fuel or energy crops. These crops an
grown specifically for energy use and inelude corn, maize and wheat crops, waste straw, willow and popula
trees, sawdust, reed canary grass, cord grasses,jerusalem artichoke, myscanthus andsorghumplants. Then
is alsoongoing researchanddevelopment into the useof municipal salidwastes to produceethanol fuel.
The principie fuel used as a petral substitute for road transport vehieles is bioethanol. Bioethanol fuel i
mainly produced by the sugar fermentation process, although it can also be manufactured by the chemica
processof reacting e.thylenewith steam.
What isBioethanol?
1. Storage
2. Canecrushing andjuice extraction
3.Dilution
4. Hydrolysis for starch andwoody biomass
S. Fermentation with yeast andenzymes
6. C02starage andethanol recapture
7. Evaparation
8. Distillation
9. Wastewater treatment
10. FuelStorage
_Dependingon the biomasssource the steps generally inelude:
!
TECHNICAL ENGLlSH3 : 2011 US
37
Ethanol canbe produced from biomass bythe hydrolysis and sugar fermentation processes,Biomasswastes
containa complex mixture of carbohyrate polvmers from the plant cell walls known as cellulose. hemi
celluloseand lignin. In order to produce sugars from the blornass, the bomass is pre-treated with acids or
enzymes inorder to reduce the sizeof the feedstock andto open up the plant structure. The cellulose andthe
hemicelluloseportions are broken down (hydrolysed) by enzymes or dilute acids into sucrose sugar that is
thenfermentedinto ethanol. The IIgnin which is also present in the biomass is normally usedas a fuel for the
ethanol production plants boilers. There are three principie methods of extracting sugarsfrom biomass. Tnese
areconcentratedacidhydrolysis, dilute acidhydrolysisandenzymatic hydrolysis.
BioethanolProduction
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Anotheradvantage of bioethanol is the easewith which it can be easily integrated into the existing road
transportfuel system. In quantities up to 5%, bioethanol can be blended with conventional fuel without the
needof enginemodifications. Bioethanol is produced usingfamiliar methods, suchas fermentation, and it can
bedistributedusingthe samepetrol forecourts andtransportation systemsas before.
By encouragingbioethanol's use, the rural economy would also receive a boost from growing the necessary
crops. Bioethanol is also biodegradable and far lesstoxic that fossil fuels. In addition, by using bioethanol in
olderenginescan help reduce the amount of carbon monoxide produced by the vehicle thus improving air
quality.
TECHNICAL ENGLlSH 3 2011 USAC
3 !
3. Distillation: After fermentation, we haveto makethe purity of ethanol higher. Distillation is one of thE
steps of the purifications. Distillation is the method to separate two liquid utlizing their differen
boiling points.
2. Fermentation:
Yeast is a facultative anaerobe. In an aerobic
environment, lt converts sugarsinto carbon dioxide and
water. In an anaerobic environment, it converts sugars
into carbon dioxide and ethanol. Thus, for an ethanol
industry, it is important to exclude significant oxygen
from its system. This fermentation process is relatively
slow process, so it is important for an industrial useto
make it faster. Usually, a propagation tank is employed.
Inthis tank, mash, water, enzymes, nutrients, and veas!
are mixedto re-hydrate the yeast.
pieces. Around the rolls there are some trenches to
improve the effectiveness of the crush. Also, the
rotating speeds of two rollers are different in order to
generate more stress on the cornoFinally, screening is
implemented at the bottom of the mll. Then, the fine
particles can pass the screen, and the big particles,
which cannot match the required size, become the
subject of the grinding again.
~~
Fttmented_ is
~ IntoaIcdlcI ,lid
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Elv)ns~~InIo~ A roller mili hassorne roll pairs consisting of two rollers.
Corn is pressed by two rollers and crushed into small
First, starch should be exposedfrom the peel of cornto
contact with water. Also, grinding makes corn small
pieces, which can increase its surface area. Then, the
increase in its surface area can enhance the contact
between starch and water. Two types of milis, a roller
mili and a harnrner mili, are usually employed. For an
industrial use, a harnmer mili is mostly used becauseof
its accuracyand its appHcationfor large amount.
1 . Gri ndi ngGrai n
Production Process:
.
39
Bioethanol has mostly been used as a biofuel for transport, especially in Brazil. Indeed it was in Brazil
where the first bioethanol fuelled carsemerged on a large-scale. Although generally unknown to the
average consumer, a large volume of bioethanol isalready usedin Europeas it is blended with petrol at 5%.
It is usedas asubstitute for lead asanoxygenating additive andhasa high octane rating, which improves
performance. Although the eventual target is the prvate consumer, few are aware of bioethanol's
potenial to, at least, partly replace petrol as a transport fuel in Europe.
Transport Fuet:
A number of chemicals are produced in the ethanol industry and potentially even more in the 2nd
generation bioethanol industry, serving a wide range of uses in the pharmaceuticals, cosmetics, beverages
andmedical sectors aswell as for industrial uses. The market potential for bioethanol is therefore not just
limited to transport fuel or energy production but haspotential to supply the existing chemicals industry.
Chemicals
Bioethanol Use
ROII pa1f
Dehvery
device
As stated aboye, after traditional distillation, about 5% of
water remains in ethanol. Especially, this water is a big
problem for fuel ethanol because the presence of this
amount of water enhances the molecular polarity of
ethanol for example ethanol and gasoline are mixed, they
separate into two phases, ethanol phase and gasoline
phase. It is easyto imagine that this inhomogeneous fuel
is not acceptable. Thus, dehydration canbeanother issue.
4. Dehydration
However, to achieve high purification, several distillations are required. This is becauseall materials have
ntermolecular interactions with each other, and two
materals will co-distill during distillation. This means that
proportion between two materials, in this case ethanol
andwater, canbechanged, still, there aretwo materials in
both layers, the liquid andthe vapor layers.
TECHNICAL ENGLlSH3 2011 USAC
Second
ron pau
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Fuel cells are another potential
area for ethanol use to produce
heat and power. Fuel cells
function by combining the fuel
hydrogen with oxygenfromthe air
to produce electrical energy, with
water vapour and heat as by-
products. Fuel Cells have a
typical electrical efficiency of
between 30 and 60 % and an
overall efficiency, if using the heat
by-product, of 70-90 %. The units
run with very 10\V noise
emissions and pollutant gas
emissions are also reduced
Fuel Cells:
bioethanol producers
fuel suppliers
car manufacturers
the government
Stakeholdersinthe BioethanolFuelMarket:
41
EM'GY EI I I CI .MY
EI I \dlI OI hola010 ... to negall\e ""1 011<-'11) \o1luo
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of ene,qy uso<!rOl ds p,odoc100n
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lalld 'oI tI lCh ,mpacls
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loo.
Therefore, there are still so many concerns to saybioethnaol is areal ideal energy source.
ln addition, an lncrease in the demand of bloethanol may burden on our money. This is because, currently,
ethanol production ls supported by huge subsidies coming from our tax. Besides, an increase in the ethanol
production means an increasein the demand of corn . This may causean lncreasein the corn price. Today, corn
is everywhere Inour mea!.
Bloethanol has some deficit. Next figure shows some environmental impacts of ethanol in gasoline.
Although, some of them may be exaggerated, but thls approach is very important when we are considering
bioethanol from overall environmental aspects. Corn production causes more soil erosion and uses more
herblcides andinsecticides. Also, wastewater from ethanol plant is alsoanother big problem.
Negatlvesides of Bloethanol
considerably. It's disadvantages areits relatlvely highcost and their short life span (regular replacement of
components). They are, however, regarded as very reliable for the duration of thelr lifespan and are often
used for emergency power.
1
TECHNICAL ENGLlSH 3 2011 USAC
4
1.- Usethe boxbeJ owto describe the picture of the BioethanoJ production where you canseethe different
steps of the process:
Activities
I TECHNI CAL ENGLlSH 3 2011 USAC
43
The most common blend is 10%ethanol and90%petrol (E10):
After fermentation comes Grinding in Bioethanol production:
An increase inthe ethanol production meansaninreasein the demand of cornoThis may causeadecreasein
the corn price.
Fuel Cells have a typical electrical efficiency of between 30 and 60%
Byencouraging bioethanol's use,the rural economywould never receive a boost from growing the necessary
crops:
Ethanol canbe produced from biomassbythe hydrolysis andsugarfermentation processes.
2. Write True or Falseaccording to the sentence:
TECHNICAL ENGLlSH 3 2011 uSAC
I
44
Write a comment about the importance of Bioethanol in the economy of a country:
,
TECHNICAL ENGLlSH 3 2011 USA C
4S
Cool.a<>
I
3. With the next picture do a"Proecess diagram" to reeognizethe activity in eaehpart of the Bioethanol
production writing eaehspeeification inthe square below.
TECHNICAL ENGLlSH 3 2011 USAC