Search results for: batch process monitoring

Authors: Rubia Gaur, Surindra Suthar

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The present study investigates the anaerobic co-digestion of duckweed (Lemna gibba) and waste activated sludge (WAS) of different proportions with acclimatized anaerobic granular sludge (AAGS) as inoculum in mesophilic conditions. Batch experiments were performed in 500 mL capacity reagent bottles at 300C temperature. Varied combinations of pre-treated duckweed biomass with constant volume of anaerobic inoculum (AAGS - 100 mL) and waste activated sludge (WAS - 22.5 mL) were devised into five batch tests. The highest methane generation was observed with batch study, T4. The Gompertz model fits well on the experimental data of the batch study, T4. The values of correlation coefficient were achieved relatively higher (R2 ≥ 0.99). The co-digestion without pre-treatment of both duckweed and WAS shows poor generation of methane gas.

Keywords: aquatic weed, biogas, biomass, Gompertz equation, waste activated sludge

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Authors: César Huiliñir, Danilo Villanueva, Pedro Iván Alvarez, Francisco Cubillos

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Biodrying aims at removing water from biowastes and has been mostly studied for municipal solid wastes (MSW), while few studies have dealt with secondary sludge from the paper and pulp industry. The goal of this study was to investigate the effect of initial moisture content (MC) on the batch biodrying of pulp and paper secondary sludge, using rice husks as bulking agents. Three initial MCs were studied (54, 65, and 74% w.b.) in closed batch laboratory-scale reactors under adiabatic conditions and with a constant air-flow rate (0.65 l min-1 kg-1 wet solid). The initial MC of the mixture of secondary sludge and rice husks showed a significant effect on the biodrying process. Using initial moisture content between 54-65% w.b., the solid moisture content was reduce up to 37 % w.b. in ten days, getting calorific values between 8000-9000 kJ kg-1. It was concluded that a decreasing of initial MC improves the drying rate and decreases the solid volatile consumption, therefore, the optimization of biodrying should consider this parameter.

Keywords: biodrying, secondary sludge, initial moisture content, pulp and paper industry, rice husk

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Authors: Hyun-Woo Cho

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The detection and identification of multivariate manufacturing processes are quite important in order to maintain good product quality. Unusual behaviors or events encountered during its operation can have a serious impact on the process and product quality. Thus they should be detected and identified as soon as possible. This paper focused on the efficient representation of process measurement data in detecting and identifying abnormalities. This qualitative method is effective in representing fault patterns of process data. In addition, it is quite sensitive to measurement noise so that reliable outcomes can be obtained. To evaluate its performance a simulation process was utilized, and the effect of adopting linear and nonlinear methods in the detection and identification was tested with different simulation data. It has shown that the use of a nonlinear technique produced more satisfactory and more robust results for the simulation data sets. This monitoring framework can help operating personnel to detect the occurrence of process abnormalities and identify their assignable causes in an on-line or real-time basis.

Keywords: detection, monitoring, identification, measurement data, multivariate techniques

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Authors: Tumisang Seodigeng, Hilary Rutto

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In this study we investigate the use of a laboratory batch digester to derive kinetic parameters for anaerobic digestion of garden grass and cattle dung. Laboratory experimental data from a 5 liter batch digester operating at mesophilic temperature of 32 C is used to derive parameters for Michaelis-Menten kinetic model. These fitted kinetics are further used to predict the scale-up parameters of a batch digester using DynoChem modeling and scale-up software. The scale-up model results are compared with performance data from 20 liter, 50 liter, and 200 liter batch digesters. Michaelis-Menten kinetic model shows to be a very good and easy to use model for kinetic parameter fitting on DynoChem and can accurately predict scale-up performance of 20 liter and 50 liter batch reactor based on parameters fitted on a 5 liter batch reactor.

Keywords: Biogas, kinetics, DynoChem Scale-up, Michaelis-Menten

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Authors: Sergio Celaschi, Henrique Canavarro de Alencar, Claaudecir Biazoli

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Effluent quality is of the highest priority for compliance with the permit limits of environmental protection agencies and ensures the protection of their local water system. Of the pollutants monitored, the biochemical oxygen demand (BOD) posed one of the greatest challenges. This work presents a solution for wastewater treatment plants - WWTP’s ability to react to different situations and meet treatment goals. Delayed BOD5 results from the lab take 7 to 8 analysis days, hindered the WWTP’s ability to react to different situations and meet treatment goals. Reducing BOD turnaround time from days to hours is our quest. Such a solution is based on a system of two BOD bioreactors associated with Digital Twin (DT) and Machine Learning (ML) methodologies via an Internet of Things (IoT) platform to monitor and control a WWTP to support decision making. DT is a virtual and dynamic replica of a production process. DT requires the ability to collect and store real-time sensor data related to the operating environment. Furthermore, it integrates and organizes the data on a digital platform and applies analytical models allowing a deeper understanding of the real process to catch sooner anomalies. In our system of continuous time monitoring of the BOD suppressed by the effluent treatment process, the DT algorithm for analyzing the data uses ML on a chemical kinetic parameterized model. The continuous BOD monitoring system, capable of providing results in a fraction of the time required by BOD5 analysis, is composed of two thermally isolated batch bioreactors. Each bioreactor contains input/output access to wastewater sample (influent and effluent), hydraulic conduction tubes, pumps, and valves for batch sample and dilution water, air supply for dissolved oxygen (DO) saturation, cooler/heater for sample thermal stability, optical ODO sensor based on fluorescence quenching, pH, ORP, temperature, and atmospheric pressure sensors, local PLC/CPU for TCP/IP data transmission interface. The dynamic BOD system monitoring range covers 2 mg/L < BOD < 2,000 mg/L. In addition to the BOD monitoring system, there are many other operational WWTP sensors. The CPU data is transmitted/received to/from the digital platform, which in turn performs analyses at periodic intervals, aiming to feed the learning process. BOD bulletins and their credibility intervals are made available in 12-hour intervals to web users. The chemical kinetics ML algorithm is composed of a coupled system of four first-order ordinary differential equations for the molar masses of DO, organic material present in the sample, biomass, and products (CO₂ and H₂O) of the reaction. This system is solved numerically linked to its initial conditions: DO (saturated) and initial products of the kinetic oxidation process; CO₂ = H₂0 = 0. The initial values for organic matter and biomass are estimated by the method of minimization of the mean square deviations. A real case of continuous monitoring of BOD wastewater effluent quality is being conducted by deploying an IoT application on a large wastewater purification system located in S. Paulo, Brazil.

Keywords: effluent treatment, biochemical oxygen demand, continuous monitoring, IoT, machine learning

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Authors: Amin Mojiri, Hamidi Abdul Aziz

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Leachate is created while water penetrates through the waste in a landfill, carrying some forms of pollutants. In literature, for treatment of wastewater and leachate, different ways of biological treatment were used. Sequencing batch reactor (SBR) is a kind of biological treatment. This study investigated the co-treatment of landfill leachate and domestic waste water by SBR and powdered activated carbon augmented (PAC) SBR process. The response surface methodology (RSM) and central composite design (CCD) were employed. The independent variables were aeration rate (L/min), contact time (h), and the ratio of leachate to wastewater mixture (%; v/v)). To perform an adequate analysis of the aerobic process, three dependent parameters, i.e. COD, color, and ammonia-nitrogen (NH3-N or NH4-N) were measured as responses. The findings of the study indicated that the PAC-SBR showed a higher performance in elimination of certain pollutants, in comparison with SBR. With the optimal conditions of aeration rate (0.6 L/min), leachate to waste water ratio (20%), and contact time (10.8 h) for the PAC-SBR, the removal efficiencies for color, NH3-N, and COD were 72.8%, 98.5%, and 65.2%, respectively.

Keywords: co-treatment, landfill Leachate, wastewater, sequencing batch reactor, activate carbon

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Authors: Jaemin Kim, Ilsun Pang, Yongrae Cho, Kwanghun Kim, Sungsun Baik

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Manufacturing cost reduction is becoming more important due to excessive oversupply of Single crystalline ingot in recent solar market. Many companies are carrying out extensive research to grow more than one Single crystalline ingot in one batch to reduce manufacturing cost. However what most companies are finding difficult in this process is the effect on ingot due to increasing levels of impurities. Every ingot leaves a certain amount of melt after it is fully grown. This is the impurity that lowers the ingot quality. This impurity increase in the batch after second, third and more are grown subsequently in one batch. In order to solve this problem, the experiment to remove the residual melt in high temperature of hot zone was performed and succeeded. Theoretical average metal concentration of second ingot by new method was calculated and compared to it by conventional method.

Keywords: single crystal, solar cell, metal impurity, Ingot

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Authors: Aadila Cayenne, Hinrich Uellendahl

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Optimization of the anaerobic digestion (AD) process of halophytic plants is essential as the biomass contains a high salt content that can inhibit the AD process. Anaerobic co-digestion, together with manure, can resolve the inhibitory effects of saline biomass in order to dilute the salt concentration and establish favorable conditions for the microbial consortia of the AD process. The present laboratory study investigated the co-digestion of S. ramosissima (Sram), and pig manure (PM) in batch and semi-continuous stirred tank reactors (CSTR) under mesophilic (38oC) conditions. The 0.5L batch reactor experiments were in mono- and co-digestion of Sram: PM using different percent volatile solid (VS) based ratios (0:100, 15:85, 25:75, 35:65, 50:50, 100:0) with an inoculum to substate (I/R) ratio of 2. Two 5L CSTR systems (R1 and R2) were operated for 133 days with a feed of PM in a control reactor (R1) and with a co-digestion feed in an increasing Sram VS ratio of Sram: PM of 15:85, 25:75, 35:65 in reactor R2 at an organic loading rate (OLR) of 2 gVS/L/d and hydraulic retention time (HRT) of 20 days. After a start-up phase of 8 weeks for both reactors R1 and R2 with PM feed alone, the halophyte biomass Sram was added to the feed of R2 in an increasing ratio of 15 – 35 %VS Sram over an 11-week period. The process performance was monitored by pH, total solid (TS), VS, total nitrogen (TN), ammonium-nitrogen (NH4 – N), volatile fatty acids (VFA), and biomethane production. In the batch experiments, biomethane yields of 423, 418, 392, 365, 315, and 214 mL-CH4/gVS were achieved for mixtures of 0:100, 15:85, 25:75, 35:65, 50:50, 100:0 %VS Sram: PM, respectively. In the semi-continuous reactor processes, the average biomethane yields were 235, 387, and 365 mL-CH4/gVS for the phase of a co-digestion feed ratio in R2 of 15:85, 25:75, and 35:65 %VS Sram: PM, respectively. The methane yield of PM alone in R1 was in the corresponding phases on average 260, 388, and 446 mL-CH4/gVS. Accordingly, in the continuous AD process, the methane yield of the halophyte Sram was highest at 386 mL-CH4/gVS in the co-digestion ratio of 25:75%VS Sram: PM and significantly lower at 15:85 %VS Sram: PM (100 mL-CH4/gVS) and at 35:65 %VS Sram (214 mL-CH4/gVS). The co-digestion process showed no signs of inhibition at 2 – 4 g/L NH4 – N, 3.5 – 4.5 g/L TN, and total VFA of 0.45 – 2.6 g/L (based on Acetic, Propionic, Butyric and Valeric acid). This study demonstrates that a stable co-digestion process of S. ramosissima and pig manure can be achieved with a feed of 25%VS Sram at HRT of 20 d and OLR of 2 gVS/L/d.

Keywords: anaerobic co-digestion, biomethane production, halophytes, pig manure, salicornia ramosissima

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Authors: Nhat-To Huynh, Chen-Fu Chien

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Textile batch dyeing scheduling problem is complicated which includes batch formation, batch assignment on machines, batch sequencing with sequence-dependent setup time. Most manufacturers schedule their orders manually that are time consuming and inefficient. More power methods are needed to improve the solution. Motivated by the real needs, this study aims to propose approaches in which genetic algorithm is developed with multi-subpopulation and hybridised with estimation of distribution algorithm to solve the constructed problem for minimising the makespan. A heuristic algorithm is designed and embedded into the proposed algorithms to improve the ability to get out of the local optima. In addition, an empirical study is conducted in a textile company in Taiwan to validate the proposed approaches. The results have showed that proposed approaches are more efficient than simulated annealing algorithm.

Keywords: estimation of distribution algorithm, genetic algorithm, multi-subpopulation, scheduling, textile dyeing

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Authors: Ife O. Bolaji

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Environmental concerns arising from the use of fossil fuels has increased the interest in the development of renewable and sustainable sources of energy. This would minimize the dependence on fossil fuels and serve as future alternatives. Organic wastes contain carbohydrates, proteins and lipids, which can be utilised as carbon sources for the production of bio-based products. Cellulose is the most abundant natural biopolymer, being the main structural component of lignocellulosic materials. The aim of this project is to develop a biological process for the hydrolysis and fermentation of organic wastes into ethanol and organic acids. The hydrolysis and fermentation processes are integrated in a single vessel using undefined mixed culture microorganisms. The anaerobic fermentation of microcrystalline cellulose was investigated in continuous and batch reactors at 25°C with an appropriate growth medium for cellulase formation, hydrolysis, and fermentation. The reactors were inoculated with soil (B1, C1, C3) or sludge from an anaerobic digester (B2, C2) and the breakdown of cellulose was monitored by measuring the production of ethanol, organic acids and the residual cellulose. The batch reactors B1 and B2 showed negligible microbial activity due to inhibition while the continuous reactors, C1, C2 and C3, exhibited little cellulose hydrolysis which was concealed by the cellulose accumulation in the reactor. At the end of the continuous operation, the reactors C1, C2 and C3 were operated under batch conditions. 48%, 34% and 42% cellulose had been fermented by day 88, 55 and 55 respectively of the batch fermentation. Acetic acid, ethanol, propionic acid and butyric acids were the main fermentation products in the reactors. A stable concentration of 0.6 g/l ethanol and 5 g/L acetic acid was maintained in C3 for several weeks due to reduced activity of methanogens caused by the decrease in pH. Thus far, the results have demonstrated that mixed microbial culture is capable of hydrolysing and fermenting cellulose under lenient conditions. The fermentation of cellulose has been found effective in a combination of continuous and batch processes.

Keywords: cellulose, hydrolysis, mixed culture, organic waste

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Authors: M. Firoz Kalam, Wilfried Schuetz, Jan Hendrik Bredehoeft

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In this research, diesel oil properties, such as aniline point, density, diesel index, cetane index and cetane number before and after treatment were studied. The investigation was considered for diesel oil samples after batch adsorption process using powdered activated carbon. Batch distillation process was applied to all treated diesel oil samples for separation of the solid-liquid mixture. The diesel oil properties were studied to observe the impact of adsorptive desulfurization process on fuel quality. Results showed that the best cetane number for desulfurized diesel oil was found at the best-operating conditions 60℃, 10g activated carbon and 180 minute contact time. The best-desulfurized diesel oil cetane number was obtained around 51 while the cetane number of untreated diesel oil was 34. Results also showed that the calculated cetane number increases as the operating temperature and amounts of adsorbent increases. This behavior was same for other diesel oil properties such as aniline point, diesel index, cetane index and density. The best value for all the fuel properties was found at same operating conditions mentioned above. Thus, it can be concluded that adsorptive desulfurization using powdered activated carbon as adsorbent had significantly improved the fuel quality of diesel oil by reducing aromatic contents of diesel oil.

Keywords: activated carbon, adsorption, desulfurization, diesel oil, fuel quality

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Authors: Khairul Bariah Sulaiman, Tajul Aris Yang

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Fermentation is well known as an essential process in cocoa beans. Besides to develop the precursor of cocoa flavour, it also induce the colour changes in the beans.The fermentation process is reported to be influenced by duration of pod storage and fermentation. Therefore, this study was conducted to evaluate colour of Malaysian cocoa beans and how the pods storage and fermentation duration using shallow box technique will effect on it characteristics. There are two factors being studied ie duration of cocoa pod storage (0, 2, 4, and 6 days) and duration of cocoa fermentation (0, 1, 2, 3, 4 and 5 days). The experiment is arranged in 4 x 6 factorial design with 24 treatments and arrangement is in a Completely Randomised Design (CRD). The produced beans is inspected for colour changes under artificial light during cut test and divided into four groups of colour namely fully brown, purple brown, fully purple and slaty. Cut tests indicated that cocoa beans which are directly dried without undergone fermentation has the highest slaty percentage. However, application of pods storage before fermentation process is found to decrease the slaty percentage. In contrast, the percentages of fully brown beans start to dominate after two days of fermentation, especially from four and six days of pods storage batch. Whereas, almost all batch have percentage of fully purple less than 20%. Interestingly, the percentage of purple brown beans are scattered in the entire beans batch regardless any specific trend. Meanwhile, statistical analysis using General Linear Model showed that the pods storage has a significant effect on the colour characteristic of the Malaysian dried beans compared to fermentation duration.

Keywords: cocoa beans, colour, fermentation, shallow box

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Authors: R. Simutis, V. Galvanauskas, D. Levisauskas, J. Repsyte, V. Grincas

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This paper deals with advanced state estimation algorithms for estimation of biomass concentration and specific growth rate in a typical fed-batch biotechnological process. This biotechnological process was represented by a nonlinear mass-balance based process model. Extended Kalman Filter (EKF) and Particle Filter (PF) was used to estimate the unmeasured state variables from oxygen uptake rate (OUR) and base consumption (BC) measurements. To obtain more general results, a simplified process model was involved in EKF and PF estimation algorithms. This model doesn’t require any special growth kinetic equations and could be applied for state estimation in various bioprocesses. The focus of this investigation was concentrated on the comparison of the estimation quality of the EKF and PF estimators by applying different measurement noises. The simulation results show that Particle Filter algorithm requires significantly more computation time for state estimation but gives lower estimation errors both for biomass concentration and specific growth rate. Also the tuning procedure for Particle Filter is simpler than for EKF. Consequently, Particle Filter should be preferred in real applications, especially for monitoring of industrial bioprocesses where the simplified implementation procedures are always desirable.

Keywords: biomass concentration, extended Kalman filter, particle filter, state estimation, specific growth rate

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Authors: A. D. Susanti, W. B. Sediawan, S. K. Wirawan, Budhijanto, Ritmaleni

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Rice bran oil contains significant amounts of oryzanol, a natural antioxidant that considered has higher antioxidant activity than vitamin E (tocopherol). Oryzanol reviewed has several health properties and interested in pharmacy, nutrition, and cosmetics. For practical usage, isolation and purification would be necessary due to the low concentration of oryzanol in crude rice bran oil (0.9-2.9%). Batch chromatography has proved as a promising process for the oryzanol recovery, but productivity was still low and scale-up processes of industrial interest have not yet been described. In order to improve productivity of batch chromatography, a continuous chromatography design namely Simulated Moving Bed (SMB) concept have been proposed. The SMB concept has interested for continuous commercial scale separation of binary system (oryzanol and rice bran oil), and rice bran oil still obtained as side product. Design of SMB chromatography for oryzanol separation requires quantification of its equilibrium. In this study, equilibrium of oryzanol separation conducted in batch adsorption using silica as the adsorbent and n-hexane/acetone (9:1) as the eluent. Three isotherm models, namely the Henry, Langmuir, and Freundlich equations, have been applied and modified for the experimental data to establish appropriate correlation for each sample. It turned out that the model quantitatively describe the equilibrium experimental data and will directed for design of SMB chromatography.

Keywords: adsorption, equilibrium, oryzanol, rice bran oil, simulated moving bed

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Authors: Hyun-Woo Cho

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It is quite important to utilize right time and intelligent production monitoring and diagnosis of industrial processes in terms of quality and safety issues. When compared with monitoring task, fault diagnosis represents the task of finding process variables responsible causing a specific fault in the process. It can be helpful to process operators who should investigate and eliminate root causes more effectively and efficiently. This work focused on the active use of combining a nonlinear statistical technique with a preprocessing method in order to implement practical real-time fault identification schemes for data-rich cases. To compare its performance to existing identification schemes, a case study on a benchmark process was performed in several scenarios. The results showed that the proposed fault identification scheme produced more reliable diagnosis results than linear methods. In addition, the use of the filtering step improved the identification results for the complicated processes with massive data sets.

Keywords: diagnosis, filtering, nonlinear statistical techniques, process monitoring

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Authors: Chen-Fang Tsai, Shin-Li Lu

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Distribution-free control chart is an oncoming area from the statistical process control charts in recent years. Some researchers have developed various nonparametric control charts and investigated the detection capability of these charts. The major advantage of nonparametric control charts is that the underlying process is not specifically considered the assumption of normality or any parametric distribution. In this paper, two nonparametric exponentially weighted moving average (EWMA) control charts based on nonparametric tests, namely NE-S and NE-M control charts, are proposed for monitoring process variability. Generally, weighted moving average (GWMA) control charts are extended by utilizing design and adjustment parameters for monitoring the changes in the process variability, namely NG-S and NG-M control charts. Statistical performance is also investigated on NG-S and NG-M control charts with run rules. Moreover, sensitivity analysis is performed to show the effects of design parameters under the nonparametric NG-S and NG-M control charts.

Keywords: Distribution-free control chart, EWMA control charts, GWMA control charts

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Authors: Hyun-Woo Cho

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The monitoring of industrial production quality has to be implemented to alarm early warning for unusual operating conditions. Furthermore, identification of their assignable causes is necessary for a quality control purpose. For such tasks many multivariate statistical techniques have been applied and shown to be quite effective tools. This work presents a process data-based monitoring scheme for production processes. For more reliable results some additional steps of noise filtering and preprocessing are considered. It may lead to enhanced performance by eliminating unwanted variation of the data. The performance evaluation is executed using data sets from test processes. The proposed method is shown to provide reliable quality control results, and thus is more effective in quality monitoring in the example. For practical implementation of the method, an on-line data system must be available to gather historical and on-line data. Recently large amounts of data are collected on-line in most processes and implementation of the current scheme is feasible and does not give additional burdens to users.

Keywords: detection, filtering, monitoring, process data

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Authors: Hyun-Woo Cho

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Continuous monitoring of industrial plants is one of necessary tasks when it comes to ensuring high-quality final products. In terms of monitoring and diagnosis, it is quite critical and important to detect some incipient abnormal events of manufacturing processes in order to improve safety and reliability of operations involved and to reduce related losses. In this work a new multivariate statistical online diagnostic method is presented using a case study. For building some reference models an empirical discriminant model is constructed based on various past operation runs. When a fault is detected on-line, an on-line diagnostic module is initiated. Finally, the status of the current operating conditions is compared with the reference model to make a diagnostic decision. The performance of the presented framework is evaluated using a dataset from complex industrial processes. It has been shown that the proposed diagnostic method outperforms other techniques especially in terms of incipient detection of any faults occurred.

Keywords: data mining, empirical model, on-line diagnostics, process fault, process monitoring

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Authors: Arne Koschel

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This article discusses event monitoring options for heterogeneous event sources as they are given in nowadays heterogeneous distributed information systems. It follows the central assumption, that a fully generic event monitoring solution cannot provide complete support for event monitoring; instead, event source specific semantics such as certain event types or support for certain event monitoring techniques have to be taken into account. Following from this, the core result of the work presented here is the extension of a configurable event monitoring (Web) service for a variety of event sources. A service approach allows us to trade genericity for the exploitation of source specific characteristics. It thus delivers results for the areas of SOA, Web services, CEP and EDA.

Keywords: event monitoring, ECA, CEP, SOA, web services

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Authors: Victor A. Okenyi, Kehinde A. Alawode

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Corrosion of reinforcement in concrete structures remains a durability issue in structural engineering with the increasing cost of repair and maintenance. The mechanism and factors influencing reinforcement corrosion in concrete with various electrochemical monitoring techniques including non-destructive, destructive techniques and the roles of sensors have been reviewed with the aim of determining the monitoring technique that proved most effective in determining corrosion parameters and more practicable for the assessment of concrete durability. Electrochemical impedance spectroscopy (EIS) and linear polarization resistance (LPR) techniques showed great performance in evaluating corrosion kinetics and corrosion rate, respectively, while the gravimetric weight loss (GWL) technique provided accurate measurements. However, no single monitoring technique showed to be the ultimate technique, and this calls for more research work in the development of more dynamic monitoring tools capable of considering all possible corrosion factors in the corrosion monitoring process.

Keywords: corrosion, concrete structures, durability, non-destructive technique, sensor

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Authors: Hyun-Woo Cho

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For ensuring the safety of a manufacturing process one should quickly identify an assignable cause of a fault in an on-line basis. To this end, many statistical techniques including linear and nonlinear methods have been frequently utilized. However, such methods possessed a major problem of small sample size, which is mostly attributed to the characteristics of empirical models used for reference models. This work presents a new method to overcome the insufficiency of measurement data in the monitoring and diagnosis tasks. Some quasi-measurement data are generated from existing data based on the two indices of similarity and importance. The performance of the method is demonstrated using a real data set. The results turn out that the presented methods are able to handle the insufficiency problem successfully. In addition, it is shown to be quite efficient in terms of computational speed and memory usage, and thus on-line implementation of the method is straightforward for monitoring and diagnosis purposes.

Keywords: data analysis, diagnosis, monitoring, process data, quality control

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Authors: Chung-Chih Lin, Chien-Liang Wu

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The detection of the polymer melt state during manufacture process is regarded as an efficient way to control the molded part quality in advance. Online monitoring rheological property of polymer melt during processing procedure provides an approach to understand the melt state immediately. Rheological property reflects the polymer melt state at different processing parameters and is very important in injection molding process especially. An approach that demonstrates how to calculate rheological property of polymer melt through in-process measurement, using injection molding as an example, is proposed in this study. The system consists of two sensors and a data acquisition module can process the measured data, which are used for the calculation of rheological properties of polymer melt. The rheological properties of polymer melt discussed in this study include shear rate and viscosity which are investigated with respect to injection speed and melt temperature. The results show that the effect of injection speed on the rheological properties is apparent, especially for high melt temperature and should be considered for precision molding process.

Keywords: injection molding, melt viscosity, shear rate, monitoring

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Authors: Gokhan Kilic, Pelin Celik

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Structural health monitoring (SHM) is widely used in evaluating the state and health of membrane structures. In the past, in order to collect data and send it to a data collection unit on membrane structures, wire sensors had to be put as part of the SHM process. However, this study recommends using wireless sensors instead of traditional wire ones to construct an economical, useful, and easy-to-install membrane structure health monitoring system. Every wireless sensor uses a software translation program that is connected to the monitoring server. Operational neural networks (ONNs) have recently been developed to solve the shortcomings of convolutional neural networks (CNNs), such as the network's resemblance to the linear neuron model. The results of using ONNs for monitoring to evaluate the structural health of a membrane are presented in this work.

Keywords: wireless sensor network, non-destructive testing, operational neural networks, membrane structures, dynamic monitoring

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Authors: Nayif Alrasheedi, Sultan Almutairi

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Field-wide, a water supply wells’ downhole corrosion inhibition program is being applied to maintain downhole component integrity and keep the fluid corrosivity below 5 MPY. Batch treatment is currently used to inject the oil field chemical. This work is a case study consisting of analytical procedures used to optimize the frequency of the good corrosion inhibition treatments. During the study, a corrosion cell was fitted with a special three-electrode configuration for electrochemical measurements, electrochemical linear polarization, corrosion monitoring, and microbial analysis. This study revealed that the current practice is not able to mitigate material corrosion in the downhole system for more than three months.

Keywords: downhole corrosion inhibition, electrochemical measurements, electrochemical linear polarization, corrosion monitoring

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Authors: Suraya Mohamad Nadzir, Badrol Ahmad, Norlia Berahim

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T91 steel has been used as construction material for superheater tubes in sub-critical and super critical boiler. This steel was developed with higher creep strength property as compared to conventional low alloy steel. However, this steel is also susceptible to materials degradation due to its sensitivity to heat treatment especially Post Weld Heat Treatment (PWHT) after weld repair process. Review of PWHT process shows that the holding temperature may different from one batch to other batch of samples depending on the material composition. This issue was reviewed by many researchers and one of the potential solutions is the development of weld repair process without PWHT. This process is possible with the use of temper bead welding technique. However, study has shown the hardness value across the weld joint with exception of PWHT is much higher compare to recommended hardness value. Based on the above findings, a study to evaluate the microstructure and hardness changes of T91 weld joint after heating at 560°C at varying duration was carried out. This study was carried out to evaluate the possibility of self-tempering process during in-service period. In this study, the T91 weld joint was heat-up in air furnace at 560°C for duration of 50 and 150 hours. The heating process was controlled with heating rate of 200°C/hours, and cooling rate about 100°C/hours. Following this process, samples were prepared for the microstructure examination and hardness evaluation. Results have shown full tempered martensite structure and acceptance hardness value was achieved after 50 hours heating. This result shows that the thin component such as T91 superheater tubes is able to self-tempering during service hour.

Keywords: T91, weld-joint, tempered martensite, self-tempering

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Authors: Yihua Wang, Yunru Lai

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Statistical process control has been successfully applied in a variety of industries. In some applications, the quality of a process or product is better characterized and summarized by a functional relationship between a response variable and one or more explanatory variables. A collection of this type of data is called a profile. Profile monitoring is used to understand and check the stability of this relationship or curve over time. The independent assumption for the error term is commonly used in the existing profile monitoring studies. However, in many applications, the profile data show correlations over time. Therefore, we focus on a general linear regression model with a first-order autocorrelation between profiles in this study. We propose an exponentially weighted moving average charting scheme to monitor this type of profile. The simulation study shows that our proposed methods outperform the existing schemes based on the average run length criterion.

Keywords: autocorrelation, EWMA control chart, general linear regression model, profile monitoring

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Authors: Stepan Kuchar, Martin Golasowski, Radim Vavrik, Michal Podhoranyi, Boris Sir, Jan Martinovic

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The main goal of this article is to describe the online flood monitoring and prediction system Floreon+ primarily developed for the Moravian-Silesian region in the Czech Republic and the basic process it uses for running automatic rainfall-runoff and hydrodynamic simulations along with their calibration and uncertainty modeling. It takes a long time to execute such process sequentially, which is not acceptable in the online scenario, so the use of high-performance computing environment is proposed for all parts of the process to shorten their duration. Finally, a case study on the Ostravice river catchment is presented that shows actual durations and their gain from the parallel implementation.

Keywords: flood prediction process, high performance computing, online flood prediction system, parallelization

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Authors: Precious Ehiomogue, Ifechukwude Israel Ahuchaogu, Isiguzo Edwin Ahaneku

Abstract:

Vermicompost is the product of the decomposition process using various species of worms, to create a mixture of decomposing vegetable or food waste, bedding materials, and vemicast. This process is called vermicomposting, while the rearing of worms for this purpose is called vermiculture. Several works have verified the adsorption of toxic metals using vermicompost but the application is still scarce for the retention of organic compounds. This research brings to knowledge the effectiveness of earthworm waste (vermicompost) for the remediation of crude oil contaminated soils. The remediation methods adopted in this study were two soil washing methods namely, batch and column process which represent laboratory and in-situ remediation. Characterization of the vermicompost and crude oil contaminated soil were performed before and after the soil washing using Fourier transform infrared (FTIR), scanning electron microscopy (SEM), X-ray fluorescence (XRF), X-ray diffraction (XRD) and Atomic adsorption spectrometry (AAS). The optimization of washing parameters, using response surface methodology (RSM) based on Box-Behnken Design was performed on the response from the laboratory experimental results. This study also investigated the application of machine learning models [Artificial neural network (ANN), Adaptive neuro fuzzy inference system (ANFIS). ANN and ANFIS were evaluated using the coefficient of determination (R²) and mean square error (MSE)]. Removal efficiency obtained from the Box-Behnken design experiment ranged from 29% to 98.9% for batch process remediation. Optimization of the experimental factors carried out using numerical optimization techniques by applying desirability function method of the response surface methodology (RSM) produce the highest removal efficiency of 98.9% at absorbent dosage of 34.53 grams, adsorbate concentration of 69.11 (g/ml), contact time of 25.96 (min), and pH value of 7.71, respectively. Removal efficiency obtained from the multilevel general factorial design experiment ranged from 56% to 92% for column process remediation. The coefficient of determination (R²) for ANN was (0.9974) and (0.9852) for batch and column process, respectively, showing the agreement between experimental and predicted results. For batch and column precess, respectively, the coefficient of determination (R²) for RSM was (0.9712) and (0.9614), which also demonstrates agreement between experimental and projected findings. For the batch and column processes, the ANFIS coefficient of determination was (0.7115) and (0.9978), respectively. It can be concluded that machine learning models can predict the removal of crude oil from polluted soil using vermicompost. Therefore, it is recommended to use machines learning models to predict the removal of crude oil from contaminated soil using vermicompost.

Keywords: ANFIS, ANN, crude-oil, contaminated soil, remediation and vermicompost

Procedia PDF Downloads 64

Authors: Neerav Kumar, Naumaan Nayyar, Sharath Kashyap

Abstract:

Most companies see an increase in the adoption of machine learning (ML) applications across internal and external-facing use cases. ML applications vend output either in batch or real-time patterns. A complete batch ML pipeline architecture comprises data sourcing, feature engineering, model training, model deployment, model output vending into a data store for downstream application. Due to unclear role expectations, we have observed that scientists specializing in building and optimizing models are investing significant efforts into building the other components of the architecture, which we do not believe is the best use of scientists’ bandwidth. We propose a system architecture created using AWS services that bring industry best practices to managing the workflow and simplifies the process of model deployment and end-to-end data integration for an ML application. This narrows down the scope of scientists’ work to model building and refinement while specialized data engineers take over the deployment, pipeline orchestration, data quality, data permission system, etc. The pipeline infrastructure is built and deployed as code (using terraform, cdk, cloudformation, etc.) which makes it easy to replicate and/or extend the architecture to other models that are used in an organization.

Keywords: data pipeline, machine learning, AWS, architecture, batch machine learning

Procedia PDF Downloads 31

Authors: Ali W. Alattabi, Khalid S. Hashim, Hassnen M. Jafer, Ali Alzeyadi

Abstract:

This study was performed to optimise the react time (RT) and study its effects on the removal rates of nitrogen compounds in a sequencing batch reactor (SBR) treating synthetic industrial wastewater. The results showed that increasing the RT from 4 h to 10, 16 and 22 h significantly improved the nitrogen compounds’ removal efficiency, it was increased from 69.5% to 95%, 75.7 to 97% and from 54.2 to 80.1% for NH₃-N, NO₃-N and NO₂-N respectively. The results obtained from this study showed that the RT of 22 h was the optimum for nitrogen compounds removal efficiency.

Keywords: ammonia-nitrogen, retention time, nitrate, nitrite, sequencing batch reactor, sludge characteristics

Procedia PDF Downloads 334