Search results for: production process

Authors: Md. Sakinul Islam, Nhol Kao, Sati Bhattacharya, Rahul Gupta

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The objective of the study is to produce naocrystalline cellulose (NCC) from rice husk by chemical extraction process. The chemical extraction processes of this production are delignification, bleaching and hydrolysis. In order to produce NCC, raw rice husk (RRH) was grinded and converted to powder form. Powder rice husk was obtained by sieving and the particles in the 75-710 μm size range was used for experimental work. The production of NCC was conducted into the jacketed glass reactor at 80 ˚C temperature under predetermined experimental conditions. In this work NaOH (4M) solution was used for delignification process. After certain experimental time delignified powder RH was collected from the reactor then washed, bleached and finally hydrolyzed in order to degrade cellulose to nanocrystalline cellulose (NCC). For bleaching and hydrolysis processes NaOCl (20%) and H2SO4 (4M) solutions were used, respectively. The resultant products from hydrolysis was neutralized by buffer solution and analyzed by FTIR, XRD, SEM, AFM and TEM. From the analysis, NCC has been identified successfully and the particle dimension has been confirmed to be in the range of 20-50 nm. From XRD results, the crystallinity of NCC was found to be approximately 45%.

Keywords: nanocrystalline cellulose, NCC, rice husk, biomass, chemical extraction

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Authors: Mahsa Ja’fari, Mohammad R. Khosravi-Nikou, Mohsen Motavassel

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A comprehensive development towards the production of ultra-clean fuels as a feed stoke is getting to raise due to the increasing use of diesel fuels and global air pollution. Production of environmental-friendly fuels can be achievable by some limited single methods and most integrated ones. Oxidative desulfurization (ODS) presents vast ranges of technologies possessing suitable characteristics with regard to the Fenton process. Using toluene as a model fuel feed with dibenzothiophene (DBT) as a sulfur compound under various operating conditions is the attempt of this study. The results showed that this oxidative process followed a pseudo-first order kinetics. Removal efficiency of 77.43% is attained under reaction time of 40 minutes with (Fe⁺²/H₂O₂) molar ratio of 0.05 in acidic pH environment. In this research, temperature of 50 °C represented the most influential role in proceeding the reaction.

Keywords: design of experiment (DOE), dibenzothiophene (DBT), optimization, oxidative desulfurization (ODS)

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Authors: Ene Rosemary Ndidiamaka, Nwangwu Florence Chinyere

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The physiochemical properties of the melon seed oil was studied to determine its potentials as viable feed stock for biodisel production. The melon seed was extracted by solvent extraction using n-hexane as the extracting solvent. In this research, methanol was the alcohol used in the production of biodiesel, although alcohols like ethanol, propanol may also be used. Sodium hydroxide was employed for the catalysis. The melon seed oil was characterized for specific gravity, pH, ash content, iodine value, acid value, saponification value, peroxide value, free fatty acid value, flash point, viscosity, and refractive index using standard methods. The melon seed oil had very high oil content. Specific gravity and flash point of the oil is satisfactory. However, moisture content of the oil exceeded the stipulated ASRTM standard for biodiesel production. The overall results indicates that the melon seed oil is suitable for single-stage transesterification process to biodiesel production.

Keywords: biodiesel, catalyst, melon seed, transesterification

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Authors: Siti Nur Izati Azmi, Zatil Afifah Omar, Kathi Swaran, Navin Kumar

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Organophilic Clays, also known as Organoclays, is used as a viscosifier in Oil based Drilling fluids. Most often, Organophilic clay are produced from modified Sodium and Calcium based Bentonite. Many studies and data show that Organophilic Clay using Hectorite based clays provide the best yield and good fluid loss properties in an oil-based drilling fluid at a higher cost. In terms of the manufacturing process, the two common methods of manufacturing organophilic clays are a Wet Process and a Dry Process. Wet process is known to produce better performance product at a higher cost while Dry Process shorten the production time. Hence, the purpose of this study is to evaluate the various formulation of an organophilic clay and its performance vs. the cost, as well as to determine the most efficient and cost-effective method of manufacturing organophilic clays.

Keywords: organophilic clay, viscosifier, wet process, dry process

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Authors: Luís Rocha, Adam Gąska, Enrico Savio, Michael Marxer, Christoph Battaglia

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The changes observed in the last years in the field of manufacturing and production engineering, popularly known as "Fourth Industry Revolution", utilizes the achievements in the different areas of computer sciences, introducing new solutions at almost every stage of the production process, just to mention such concepts as mass customization, cloud computing, knowledge-based engineering, virtual reality, rapid prototyping, or virtual models of measuring systems. To effectively speed up the production process and make it more flexible, it is necessary to tighten the bonds connecting individual stages of the production process and to raise the awareness and knowledge of employees of individual sectors about the nature and specificity of work in other stages. It is important to discover and develop a suitable education method adapted to the specificities of each stage of the production process, becoming an extremely crucial issue to exploit the potential of the fourth industrial revolution properly. Because of it, the project “Train4Dim” (T4D) intends to develop complex training material for digital manufacturing, including content for design, manufacturing, and quality control, with a focus on coordinate metrology and portable measuring systems. In this paper, the authors present an approach to using an active learning methodology for digital manufacturing. T4D main objective is to develop a multi-degree (apprenticeship up to master’s degree studies) and educational approach that can be adapted to different teaching levels. It’s also described the process of creating the underneath methodology. The paper will share the steps to achieve the aims of the project (training model for digital manufacturing): 1) surveying the stakeholders, 2) Defining the learning aims, 3) producing all contents and curriculum, 4) training for tutors, and 5) Pilot courses test and improvements.

Keywords: learning, Industry 4.0, active learning, digital manufacturing

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Authors: Thanapat Chaireongsirikul, Apichit Svang-Ariyaskul

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An analysis of mass balance, energy performance, and environmental impact assessment were performed to evaluate bioethanol production in Thailand. Thailand is an agricultural country. Thai government plans to increase the use of alternative energy to 20 percent by 2022. One of the primary campaigns is to promote a bioethanol production from abundant biomass resources such as bitter cassava, molasses and sugarcane. The bioethanol production is composed of three stages: cultivation, pretreatment, and bioethanol conversion. All of mass, material, fuel, and energy were calculated to determine the environmental impact of three types of bioethanol production: bioethanol production from cassava (CBP), bioethanol production from molasses (MBP), and bioethanol production from rice straw (RBP). The results showed that bioethanol production from cassava has the best environmental performance. CBP contributes less impact when compared to the other processes.

Keywords: bioethanol production, biofuel, LCA, chemical engineering

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Authors: Debabrata Das, Preeti Mishra

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A two-phase anaerobic process combining biohydrogen followed by biomethane (biohythane technology) serves as an environment-friendly and economically sustainable approach for the improved valorization of organic wastes. Suitability of the pure cultures like Klebsiela pneumonia, C. freundii, B. coagulan, etc. and mixed acidogenic cultures for the biohydrogen production was already studied. The characteristics of organic wastes play a critical role in biohydrogen production. The choice of an appropriate combination of complementary organic wastes can vastly improve the bioenergy generation besides achieving the significant cost reduction. Suitability and economic viability of using the groundnut deoiled cake (GDOC), mustard deoiled cake (MDOC), distillers’ dried grain with soluble (DDGS) and algal biomass (AB) as a co-substrate were studied for a biohythane production. Results show that maximum gaseous energy of 20.7, 9.3, 16.7 and 15.6 % was recovered using GDOC, MDOC, DDGS and AB in the two stage biohythane production, respectively. Both GDOC and DDGS were found to be better co-substrates as compared to MDOC and AB in terms of hythane production, respectively. The maximum cumulative hydrogen and methane production of 150 and 64 mmol/L were achieved using GDOC. Further, 98 % reduction in substrate input cost (SIC) was achieved using the co-supplementation procedure.

Keywords: Biohythane, algal biomass, distillers’ dried grain with soluble (DDGS), groundnut deoiled cake (GDOC), mustard deoiled cake (MDOC)

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Authors: Tim Giesen, Raphael Adamietz, Pablo Mayer, Philipp Stiefel, Patrick Alle, Dirk Schlenker

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The competitiveness and success of new electrical energy storages such as battery cells are significantly dependent on a short time-to-market. Producers who decide to supply new battery cells to the market need to be easily adaptable in manufacturing with respect to the early customers’ needs in terms of cell size, materials, delivery time and quantity. In the initial state, the required output rates do not yet allow the producers to have a fully automated manufacturing line nor to supply handmade battery cells. Yet there was no solution for manufacturing battery cells in low to medium volumes in a reproducible way. Thus, in terms of cell format and output quantity, a concept for the flexible assembly of battery cells was developed by the Fraunhofer-Institute for Manufacturing Engineering and Automation. Based on clustered processes, the modular system platform can be modified, enlarged or retrofitted in a short time frame according to the ordered product. The paper shows the analysis of the production steps from a conventional battery cell assembly line. Process solutions were found by using I/O-analysis, functional structures, and morphological boxes. The identified elementary functions were subsequently clustered by functional coherences for automation solutions and thus the single process cluster was generated. The result presented in this paper enables to manufacture different cell products on the same production system using seven process clusters. The paper shows the solution for a batch-wise flexible battery cell production using advanced process control. Further, the performed tests and benefits by using the process clusters as cyber-physical systems for an integrated production and value chain are discussed. The solution lowers the hurdles for SMEs to launch innovative cell products on the global market.

Keywords: automation, battery production, carrier, advanced process control, cyber-physical system

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Authors: Andrey Norov

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Based on a comparison of technologies for the production of granular nitrate-containing and nitrate-free NPKS-fertilizers, this paper considers the effect of process parameters on the economic feasibility of production, on physical & chemical, and structural & mechanical properties and quality of final products (caking, static strength of granules, hygroscopicity, etc.), as well as on thermal stability of fertilizers, eco-friendly production, and other aspects. This comparative analysis allows to select the optimal technology for specific conditions and requirements. Additionally, the report considers flexible, a unique technology for the production of granular NPKS-fertilizers containing sulfur and calcium, suggested by Samoilov Research Institute for Mineral Fertilizers JSC “NIUIF” - the oldest industry-oriented institute in Russia. This technology is implemented at one of the Russian plants where combined drum is used for granulation and drying.

Keywords: caking, granule static strength, granulating-drying drum, NPKS-fertilizers

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Authors: Ana Paula S. Horodenski, Priscila Pelegrini, Salli Baggenstoss

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The brewing industry with artisanal concepts seeks to serve a specific market, with diversified production that has been gaining ground in the national environment, also in the Amazon region. This growth is due to the more demanding consumer, with a diversified taste that wants to try new types of beer, enjoying products with new aromas, flavors, as a differential of what is so widely spread through the big industrial brands. Thus, through qualitative research methods, the study aimed to investigate how is the process of managing the production of a craft brewery in a city in the northern State of Mato Grosso (BRAZIL), providing knowledge of production processes and strategies in the industry. With the efficient use of resources, it is possible to obtain the necessary quality and provide better performance and differentiation of the company, besides analyzing the best management model. The research is descriptive with a qualitative approach through a case study. For the data collection, a semi-structured interview was elaborated, composed of the areas: microbrewery characterization, artisan beer production process, and the company supply chain management. Also, production processes were observed during technical visits. With the study, it was verified that the artisan brewery researched develops preventive maintenance strategies with the inputs, machines, and equipment, so that the quality of the product and the production process are achieved. It was observed that the distance from the supplying centers makes the management of processes and the supply chain be carried out with a longer planning time so that the delivery of the final product is satisfactory. The production process of the brewery is composed of machines and equipment that allows the control and quality of the product, which the manager states that for the productive capacity of the industry and its consumer market, the available equipment meets the demand. This study also contributes to highlight one of the challenges for the development of small breweries in front of the market giants, that is, the legislation, which fits the microbreweries as producers of alcoholic beverages. This makes the micro and small business segment to be taxed as a major, who has advantages in purchasing large batches of raw materials and tax incentives because they are large employers and tax pickers. It was possible to observe that the supply chain management system relies on spreadsheets and notes that are done manually, which could be simplified with a computer program to streamline procedures and reduce risks and failures of the manual process. In relation to the control of waste and effluents affected by the industry is outsourced and meets the needs. Finally, the results showed that the industry uses preventive maintenance as a productive strategy, which allows better conditions for the production and quality of artisanal beer. The quality is directly related to the satisfaction of the final consumer, being prized and performed throughout the production process, with the selection of better inputs, the effectiveness of the production processes and the relationship with the commercial partners.

Keywords: artisanal brewery, production management, production processes, supply chain

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Authors: Lozano Paul

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Coupled Membrane Separation Technology (CMST), including Cross Flow Microfiltration (CFM) and Reverse Osmosis (RO), are used to concentrate microalgae biomass or/and to extract and concentrate water-soluble metabolites produced during micro-algae production cycle, as well as water recycling. Micro-algae biomass was produced using different feeding mixtures of ingredients: pure chemical origin compounds and natural/ecological water-extracted components from available local plants. Micro-algae was grown either in conventional plastic bags (100L/unit) or in small-scale innovative bioreactors (75L). Biomass was concentrated as CFM retentate using a P19-60 ceramic membrane (0.2μm pore size), and water-soluble micro-algae metabolites left in the CFM filtrate were concentrated by RO. Large volumes of water (micro-algae culture media) of were recycled by the CMTS for another biomass production cycle.

Keywords: extraction, membrane process, microalgae, natural compound

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Authors: S. Bouchami, M.N. Lakhoua

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The automotive market is a dynamic market that continues to grow. That’s why several companies belonging to this sector adopt a quality improvement approach. Wanting to be competitive and successful in the environment in which they operate, these companies are dedicated to establishing a system of quality management to ensure the achievement of the objective quality, improving the products and process as well as the satisfaction of the customers. In this paper, the management of the quality and the improvement of a production line in an industrial company is presented. In fact, the project is divided into two essential parts: the creation of the technical line documentation and the quality assurance documentation and the resolution of defects at the line, as well as those claimed by the customer. The creation of the documents has required a deep understanding of the manufacturing process. The analysis and problem solving were done through the implementation of PDCA (Plan Do Check Act) and FTA (Fault Tree Analysis). As perspective, in order to better optimize production and improve the efficiency of the production line, a study on the problems associated with the supply of raw materials should be made to solve the problems of stock-outs which cause delays penalizing for the industrial company.

Keywords: quality management, documentary system, Plan Do Check Act (PDCA), fault tree analysis (FTA) method

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Authors: Dmitrii Starikov, Evgeny Rybakov, Denis Zhuravlev

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Plastic for 3D printing is very necessary material part for printers. But plastic production is technological process, which implies application of different control algorithms. Possible algorithms of providing set diameter of plastic fiber are proposed and described in the article. Results of research were proved by existing unit of filament production.

Keywords: ABS-plastic, automation, control system, extruder, filament, PID-algorithm

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Authors: Shashank Tiwari, S. P. Mahapatra

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The aim of this technique is to reduce the steps of process scales up, save time & cost of the industries. This technique will minimise the steps of process scale up. The new steps are, Novel Lab Scale, Novel Lab Scale Trials, Novel Trial Batches, Novel Exhibit Batches, Novel Validation Batches. In these steps, it is not divided to validation batches in three parts but the data of trials batches, Exhibit Batches and Validation batches are use and compile for production and used for validation. It also increases the batch size of the trial, exhibit batches. The new size of trials batches is not less than fifty Thousand, the exhibit batches increase up to two lack and the validation batches up to five lack. After preparing the batches all their data & drugs use for stability & maintain the validation record and compile data for the technology transfer in production department for preparing the marketed size batches.

Keywords: batches, technique, preparation, scale up, validation

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Authors: Nursac Akyol, Merve S. Turan, Mustafa Ozcelik, Erdogan Kucukoner, Erkan Karacabey

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Traditional raisin production is a long time drying process under sunlight. During this procedure, grapes are open to some environmental effects besides the adverse effects of the long drying period. Thus, there is a need to develop an alternative method being applicable instead of traditional one. To this extent, a combination of a potential pretreatment (carbonic maceration, CM) with convectional oven drying was examined. CM application was used in raisin production (grape drying) as a pretreatment process before oven drying. Pressure, temperature and time were examined as application parameters of CM. In conventional oven drying, the temperature is a process variable. The aim is to find out how CM and convectional drying processes affect the drying characteristics of grapes as well as their physical and chemical properties. For this purpose, the response surface method was used to determine both the effects of the variables and the optimum pretreatment and drying conditions. The optimum conditions of CM for raisin production were 0.3 MPa of pressure value, 4°C of application temperature and 8 hours of application time. The optimized drying temperature was 77°C. The results showed that the application of CM before the drying process improved the drying characteristics. Drying took only 389 minutes for grapes pretreated by CM under optimum conditions and 495 minutes for the control group dried only by the conventional drying process. According to these results, a decrease of 21% was achieved in the time requirement for raisin production. Also, it was observed that the samples dried under optimum conditions had similar physical properties as those the control group had. It was seen that raisin, which was dried under optimum conditions were in better condition in terms of some of the bioactive contents compared to control groups. In light of all results, it is seen that CM has an important potential in the industrial drying of grape samples. The current study was financially supported by TUBITAK, Turkey (Project no: 116R038).

Keywords: drying time, pretreatment, response surface methodlogy, total phenolic

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Authors: A. W. Zularisam, Sveta Thakur, Lakhveer Singh, Mimi Sakinah Abdul Munaim

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Clostridium sp. LS2 was immobilised by entrapment in polyethylene glycol (PEG) gel beads to improve the biohydrogen production rate from palm oil mill effluent (POME). We sought to explore and optimise the hydrogen production capability of the immobilised cells by studying the conditions for cell immobilisation, including PEG concentration, cell loading and curing times, as well as the effects of temperature and K2HPO4 (500–2000 mg/L), NiCl2 (0.1–5.0 mg/L), FeCl2 (100–400 mg/L) MgSO4 (50–200 mg/L) concentrations on hydrogen production rate. The results showed that by optimising the PEG concentration (10% w/v), initial biomass (2.2 g dry weight), curing time (80 min) and temperature (37 °C), as well as the concentrations of K2HPO4 (2000 mg/L), NiCl2 (1 mg/L), FeCl2 (300 mg/L) and MgSO4 (100 mg/L), a maximum hydrogen production rate of 7.3 L/L-POME/day and a yield of 0.31 L H2/g chemical oxygen demand were obtained during continuous operation. We believe that this process may be potentially expanded for sustained and large-scale hydrogen production.

Keywords: hydrogen, polyethylene glycol, immobilised cell, fermentation, palm oil mill effluent

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Authors: Tie-Qing Zhang, Seunghun Jung, Young-Bae Kim

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This research is devoted to developing a membrane reactor to flexibly meet the hydrogen demand of onboard fuel cells, which is an important part of green energy development. Among many renewable chemical products, dimethyl ether (DME) has the advantages of low reaction temperature (400 °C in this study), high hydrogen atom content, low toxicity, and easy preparation. Autothermal reforming, on the other hand, has a high hydrogen recovery rate and exhibits thermal neutrality during the reaction process, so the additional heat source in the hydrogen production process can be omitted. Therefore, the DME auto thermal reforming process was adopted in this study. To control the temperature of the reaction catalyst bed and hydrogen production rate, a Model Predictive Control (MPC) scheme was designed. Taking the above two variables as the control objectives, stable operation of the reformer can be achieved by controlling the flow rates of DME, steam, and high-purity air in real-time. To prevent catalyst poisoning in the fuel cell, the hydrogen needs to be purified to reduce the carbon monoxide content to below 50 ppm. Therefore, a Pd-Ag hydrogen semi-permeable membrane with a thickness of 3-5 μm was inserted into the auto thermal reactor, and the permeation efficiency of hydrogen was improved by steam purging on the permeation side. Finally, hydrogen with a purity of 99.99 was obtained.

Keywords: hydrogen production, auto thermal reforming, membrane, fuel cell

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Authors: Zouhair Issa Ahmed, Ahmed Abdulrasool Ahmed, Falah Hassan Abdulsada

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This paper presents a layout of a factory using Pro-Model simulation by choosing the best layout that gives the highest productivity and least work in process. The general problem is to find the best sequence in which jobs pass between the machines which are compatible with the technological constraints and optimal with respect to some performance criteria. The best simulation with Pro-Model program increased productivity and reduced work in process by balancing lines of production compared with the current layout of factory when productivity increased from 45 products to 180 products through 720 hours.

Keywords: scheduling, Pro-Model, simulation, balancing lines of production, layout planning, WIP

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Authors: Weiwei Xie, Yichao Li

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The initial installation of the umbilical can affect the subsequent installation process and final installation. Meanwhile, the design of both ends of the ultra-deep water dynamic umbilical (UDWDU), as well as the design of the surface unit and the subsea production system connected by UDWDU,], varies in different oil and gas fields. To optimize the installation process of UDWDU, on the basis of the summary and analysis of the surface-end and the subsea-end design of UDWDU and the mainstream construction resources, the method of initial installation from the surface unit side or the subsea production system side of UDWDU is studied, and each initiation installation method is pointed out if some difficulties that may be encountered.

Keywords: dynamic umbilical, ultra-deep-water, initial installation, installation process

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Authors: Rashid S. Mohammad, Shicheng Zhang, Sun Lu, Syed Jamal-Ud-Din, Xinzhe Zhao

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A compositional reservoir simulation model (CMG-GEM) was used for cyclic CO₂ injection process in unconventional tight reservoir. Cyclic CO₂ injection is an enhanced oil recovery process consisting of injection, shut-in, and production. The study of cyclic CO₂ injection and hydrocarbon recovery in ultra-low permeability reservoirs is mainly a function of rock, fluid, and operational parameters. CMG-GEM was used to study several design parameters of cyclic CO₂ injection process to distinguish the parameters with maximum effect on the oil recovery and to comprehend the behavior of cyclic CO₂ injection in tight reservoir. On the other hand, permeability reduction induced by asphaltene precipitation is one of the major issues in the oil industry due to its plugging onto the porous media which reduces the oil productivity. In addition to asphaltene deposition, solubility of CO₂ in the aquifer is one of the safest and permanent trapping techniques when considering CO₂ storage mechanisms in geological formations. However, the effects of the above uncertain parameters on the process of CO₂ enhanced oil recovery have not been understood systematically. Hence, it is absolutely necessary to study the most significant parameters which dominate the process. The main objective of this study is to improve techniques for designing cyclic CO₂ injection process while considering the effects of asphaltene deposition and solubility of CO₂ in the brine in order to prevent asphaltene precipitation, minimize CO₂ emission, optimize cyclic CO₂ injection, and maximize oil production.

Keywords: tight reservoirs, cyclic O₂ injection, asphaltene, solubility, reservoir simulation

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Authors: Dharmit Viroja, Prerakkumar Shah, Rajanikant Gajera, Ruchit Shah

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With present scenario of aging oil and gas fields with high water cuts, volatile oil prices and increasing greenhouse gas emission, the need for alleviating such issues has necessitated for oil and gas industry to make the maximum out of available assets, infrastructure and reserves in mother Earth. Study undertaken emphasizes on utilizing Geothermal Energy under specific reservoir conditions for Enhanced oil Recovery (EOR) to boost up production. Allied benefits of this process include mitigation of electricity problem in remote fields and controlled CO-emission. Utilization of this energy for EOR and increasing economic life of field could surely be rewarding. A new way to value oil lands would be considered if geothermal co-production is integrated in the field development program. Temperature profile of co-produced fluid across its journey is a pivotal issue which has been studied. Geo pressured reservoirs resulting from trapped brine under an impermeable bed is also a frontier for exploitation. Hot geothermal fluid is a by-product of large number of oil and gas wells, historically this hot water has been seen as an inconvenience; however, it can be looked at as a useful resource. The production of hot fluids from abandoned and co-production of hot fluids from producing wells has potential to prolong life of oil and gas fields. The study encompasses various factors which are required for use of this technology and application of this process across various phases of oil and gas value chain. Interdisciplinary approach in oil and gas value chain has shown potential for economic production of estimated oil and gas reserves.

Keywords: enhanced oil recovery, geo-pressured reservoirs, geothermal energy, oil and gas value chain

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Authors: C. Müller, T. Ortmann, S. Scholl, H. J. Jördening

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Multienzymatic catalysis can be used as an alternative to chemical synthesis or hydrolysis of polysaccharides for the production of high value oligosaccharides from cheap resources such as sucrose. However, development of multienzymatic processes is complex, especially with respect to suitable conditions for enzymes originating from different organisms. Furthermore, an optimal configuration of the catalysts in a reaction cascade has to be found. These challenges can be approached by design of experiments. The system investigated in this study is a trienzymatic catalyzed reaction which results in laminaribiose production from sucrose and comprises covalently immobilized sucrose phosphorylase (SP), glucose isomerase (GI) and laminaribiose phosphorylase (LP). Operational windows determined with design of experiments and kinetic data of the enzymes were used to optimize the enzyme ratio for maximum product formation and minimal production of byproducts. After adjustment of the enzyme activity ratio to 1: 1.74: 2.23 (SP: LP: GI), different process options were investigated in silico. The considered options included substrate dependency, the use of glucose as co-substrate and substitution of glucose isomerase by glucose addition. Modeling of batch operation in a stirred tank reactor led to yields of 44.4% whereas operation in a continuous stirred tank reactor resulted in product yields of 22.5%. The maximum yield in a bienzymatic system comprised of sucrose phosphorylase and laminaribiose phosphorylase was 67.7% with sucrose and different amounts of glucose as substrate. The experimental data was in good compliance with the process model for batch operation. The continuous operation will be investigated in further studies. Simulation of operational process possibilities enabled us to compare various operational modes regarding different aspects such as cost efficiency, with the minimum amount of expensive and time-consuming practical experiments. This gives us more flexibility in process implementation and allows us, for example, to change the production goal from laminaribiose to higher oligosaccharides.

Keywords: design of experiments, enzyme kinetics, multi-enzymatic system, in silico process development

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Authors: G. Martino, F. Silva, E. Marchal

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The control over delivered iron ore blend characteristics is one of the most important aspects of the mining business. The iron ore price is a function of its composition, which is the outcome of the beneficiation process. So, end-to-end integrated planning of mine operations can reduce risks of penalties on the iron ore price. In a standard iron mining company, the production chain is composed of mining, ore beneficiation, and client supply. When mine planning and client supply decisions are made uncoordinated, the beneficiation plant struggles to deliver the best blend possible. Technological improvements in several fields allowed bridging the gap between departments and boosting integrated decision-making processes. Clusterization and classification algorithms over historical production data generate reasonable previsions for quality and volume of iron ore produced for each pile of run-of-mine (ROM) processed. Mathematical modeling can use those deterministic relations to propose iron ore blends that better-fit specifications within a delivery schedule. Additionally, a model capable of representing the whole production chain can clearly compare the overall impact of different decisions in the process. This study shows how flexibilization combined with a planning optimization model between the mine and the ore beneficiation processes can reduce risks of out of specification deliveries. The model capabilities are illustrated on a hypothetical iron ore mine with magnetic separation process. Finally, this study shows ways of cost reduction or profit increase by optimizing process indicators across the production chain and integrating the different plannings with the sales decisions.

Keywords: clusterization and classification algorithms, integrated planning, mathematical modeling, optimization, penalty minimization

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Authors: Merve Ozer, Tolga Gokkurt, Yasemen Gokkurt, Ezgi Bozbey

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In this study, we investigated the recovery of Polyethylene terephthalate/Polypropylene (PET/PP)-containing automotive textile waste from post-product and post-consumer phases in the automotive sector according to the upcycling technique and the methods of formulation and production that would allow these wastes to be substituted as PP/PET alloys instead of original PP raw materials used in plastic edge band production. The laminated structure of the stated wastes makes it impossible to separate the incompatible PP and PET phases in content and thus produce a quality raw material or product as a result of recycling. Within the scope of a two-stage production process, a comprehensive process was examined using block copolymers and maleic grafted copolymers with different features to ensure that these two incompatible phases are compatible. The mechanical, thermal, and morphological properties of the plastic raw materials, which will be referred to as PP/PET blends obtained as a result of the process, were examined in detail and discussed their substitutability instead of the original raw materials.

Keywords: mechanical recycling, melt blending, plastic blends, polyethylene, polypropylene, recycling of plastics, terephthalate, twin screw extruders

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Authors: Krittiya Pornmai, Sumaeth Chavadej

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The increasing in global energy demand has affected the climate change caused by the generation of greenhouse gases. Therefore, the objective of this work was to investigate a direct production of synthesis gas from a CO₂-containing natural gas by using gliding arc discharge plasma technology. In this research, the effects of steam reforming, combined steam reforming and partial oxidation, and using multistage gliding arc discharge system on the process performance have been discussed. The simulated natural gas used in this study contains 70% methane, 5% ethane, 5% propane, and 20% carbon dioxide. In comparison with different plasma reforming processes (under their optimum conditions), the steam reforming provides the highest H₂ selectivity resulting from the cracking reaction of steam. In addition, the combined steam reforming and partial oxidation process gives a very high CO production implying that the addition of both oxygen and steam can offer the acceptably highest synthesis gas production. The stage number of plasma reactor plays an important role in the improvement of CO₂ conversion. Moreover, 3 stage number of plasma reactor is considered as an optimum stage number for the reforming of CO₂-containing natural gas with steam and partial oxidation in term of providing low energy consumption as compared with other plasma reforming processes.

Keywords: natural gas, reforming process, gliding arc discharge, plasma technology

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Authors: Balamurugan Baladhandapani, Ganesh Renganathan, V. R. Sanal Kumar

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In this paper a comprehensive review on various factory layouts has been carried out for designing a lucrative process layout for medium scale industries. Industry data base reveals that the end product rejection rate is on the order of 10% amounting large profit loss. In order to avoid these rejection rates and to increase the quality product production an intermediate non-destructive testing facility (INDTF) has been recommended for increasing the overall profit. We observed through detailed case studies that while introducing INDTF to medium scale industries the expensive production process can be avoided to the defective products well before its final shape. Additionally, the defective products identified during the intermediate stage can be effectively utilized for other applications or recycling; thereby the overall wastage of the raw materials can be reduced and profit can be increased. We concluded that the prudent design of a factory layout through critical path method facilitating with INDTF will warrant profitable outcome.

Keywords: intermediate non-destructive testing, medium scale industries, process layout design

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Authors: Walailak Atthirawong

Abstract:

By the end of 2015, the Association of Southeast Asian Nations (ASEAN) countries proclaim to transform into the next stage of an economic era by having a single market and production base called ASEAN Economic Community (AEC). One objective of the AEC is to establish ASEAN as a single market and one production base making ASEAN highly competitive economic region and competitive with new mechanisms. As a result, it will open more opportunities to enterprises in both trade and investment, which offering a competitive market of US$ 2.6 trillion and over 622 million people. Location decision plays a key role in achieving corporate competitiveness. Hence, it may be necessary for enterprises to redesign their supply chains via enlarging a new production base which has low labor cost, high labor skill and numerous of labor available. This strategy will help companies especially for apparel industry in order to maintain a competitive position in the global market. Therefore, in this paper a generic model for location selection decision for Thai apparel industry using Fuzzy Analytical Network Process (FANP) is proposed. Myanmar, Vietnam and Cambodia are referred for alternative location decision from interviewing expert persons in this industry who have planned to enlarge their businesses in AEC countries. The contribution of this paper lies in proposing an approach model that is more practical and trustworthy to top management in making a decision on location selection.

Keywords: apparel industry, ASEAN Economic Community (AEC), Fuzzy Analytical Network Process (FANP), location decision

Procedia PDF Downloads 212

Authors: O. Ualibek, C. Spitas, V. Inglezakis, G. Itskos

Abstract:

This study presents simulations of an aluminium melt containing an initially non-dispersed fly ash nanoparticle phase. Mixing is affected predominantly by means of forced extensional flow via either straight or slanted orifices. The sensitivity to various process parameters is determined. The simulated process is used for the production of cast fly ash-aluminium nanocomposites. The possibilities for rod and plate stock grading in the context of a continuous casting process implementation are discussed.

Keywords: metal matrix composites, fly ash nanoparticles, aluminium 2024, agglomeration

Procedia PDF Downloads 179

Authors: Ilze Dimanta, Zane Rutkovska, Vizma Nikolajeva, Janis Kleperis, Indrikis Muiznieks

Abstract:

Majority of word’s steadily increasing energy consumption is provided by non-renewable fossil resources. Need to find an alternative energy resource is essential for further socio-economic development. Hydrogen is renewable, clean energy carrier with high energy density (142 MJ/kg, accordingly – oil has 42 MJ/kg). Biological hydrogen production is an alternative way to produce hydrogen from renewable resources, e.g. using organic waste material resource fermentation that facilitate recycling of sewage and are environmentally benign. Hydrogen gas is produced during the fermentation process of bacteria in anaerobic conditions. Bacteria are producing hydrogen in the liquid phase and when thermodynamic equilibrium is reached, hydrogen is diffusing from liquid to gaseous phase. Because of large quantities of available crude glycerol and the highly reduced nature of carbon in glycerol per se, microbial conversion of it seems to be economically and environmentally viable possibility. Such industrial organic waste product as crude glycerol is perspective for usage in feedstock for hydrogen producing bacteria. The process of biodiesel production results in 41% (w/w) of crude glycerol. The developed lab-scale test system (experimental bioreactor) with hydrogen micro-electrode (Unisense, Denmark) was used to determine hydrogen production yield and rate in the liquid phase. For hydrogen analysis in the gas phase the RGAPro-100 mass-spectrometer connected to the experimental test-system was used. Fermentative bacteria strains were tested for hydrogen gas production rates. The presence of hydrogen in gaseous phase was measured using mass spectrometer but registered concentrations were comparatively small. To decrease the hydrogen partial pressure in liquid phase reactor with a system for continuous bubbling with inert gas was developed. H2 production rate for the best producer in liquid phase reached 0,40 mmol H2/l, in gaseous phase - 1,32 mmol H2/l. Hydrogen production rate is time dependent – higher rate of hydrogen production is at the fermentation process beginning when concentration increases, but after three hours of fermentation, it decreases.

Keywords: bio-hydrogen, fermentation, experimental bioreactor, crude glycerol

Procedia PDF Downloads 494

Authors: Fabian Velasquez, John Espitia, Henry Hernadez, Sebastian Escobar, Jader Rodriguez

Abstract:

Non-centrifuged cane sugar (NCS) is a concentrated product obtained through the evaporation of water contain from sugarcane juice inopen heat exchangers (OE). The heat supplied to the evaporation stages is obtained from the cane bagasse through the thermochemical process of combustion, where the thermal energy released is transferred to OE by the flue gas. Therefore, the optimization of energy usage becomes essential for the proper design of the production process. For optimize the energy use, it is necessary modeling and simulation of heat transfer between the combustion gases and the juice and to understand the major mechanisms involved in the heat transfer. The main objective of this work was simulated heat transfer phenomena between the flue gas and open heat exchangers using Computational Fluid Dynamics model (CFD). The simulation results were compared to field measured data. Numerical results about temperature profile along the flue gas pipeline at the measurement points are in good accordance with field measurements. Thus, this study could be of special interest in design NCS production process and the optimization of the use of energy.

Keywords: mathematical modeling, design variables, computational fluid dynamics, overall thermal efficiency

Procedia PDF Downloads 100