Actual Production Process Research Articles

Closed-Loop Process of Extracting and Separating Zinc Impurities from Industrial Cobalt Products—Pilot Test Study

The cobalt-containing products of an enterprise were selected as the object of this study. The separation effect of Cyanex 272 on Zn and Co was studied through a pilot test. The results showed that Cyanex 272 had a high extraction rate for Zn at pH 3–3.4, up to 99.8%. The extracted Zn2+ was enriched in the organic phase, and the Zn2+ in the organic phase was extracted back into the aqueous phase in the stripping stage by adding strong acid. Addition amounts of strong acid of 50 g·L−1, 80 g·L−1, and 100 g·L−1 were set. The results showed that the addition amounts of 80 g·L−1 and 100 g·L−1 could significantly reduce the pH of the back-extraction solution and effectively enrich Zn2+ in the solution. There was a large amount of Zn2+ in the back-extraction solution, which could be used twice to prepare zinc carbonate products through neutralization and precipitation. By comparing the extraction effect, economic cost, and resource loss under different strong acid addition amounts, it was found that the 80 g·L−1 strong acid addition amount was more suitable for the actual production process. This study provides data support and practical evidence for the selection of industrial extraction process parameters for Zn2+ separation in actual cobalt products.

A Novel Axial Load Inversion Method for Rock Bolts Based on the Surface Strain of a Bearing Plate

Anchor rock bolts are among the essential support components employed in coal mine support engineering. Measuring the axial load of the supporting anchor bolts constitutes an important foundation for evaluating the support effect and the mechanical state of the surrounding rock. The existing methods for measuring the axial load of rock bolts have difficulty meeting the actual demands in terms of accuracy and means. Therefore, we propose a novel inverse method for determining the axial load of rock bolts. On the basis of the dynamic relationship between the axial load of the anchor bolt and the strain of the plate, a calculation model for the inverse analysis of the axial load from the plate strain is presented, and it is verified and corrected through finite element analysis and indoor physical experiments. By combining the calculation model with the digital image correlation method, a low costinversion of the axial load of the anchor bolt in actual support engineering is achieved. The experimental results demonstrate that the average errors of the load inversion of anchor bolts in three different states via the theory and method proposed in this paper are less than 8.8% (4 kN), 3.6% (3.2 kN), and 14.7% (5.5 kN), respectively, and the average error of the axial load of the rock bolts in the proposed method is only 4.23 kN. It possesses relatively high accuracy and can be effectively applied in the actual production processes of mines.

Vehicle Lane Changing Game Model Based on Improved SVM Algorithm

In order to improve the autonomous lane-changing performance of unmanned vehicles, this paper aims to solve the problem of inaccurate decision classification in traditional support vector machine (SVM) algorithms applied to the lane-changing decision-making stage of intelligent driving vehicles. By using game theory-related theories and combining the improved support vector machine (SSA-SVM) method, a vehicle autonomous lane-changing strategy based on game theory is established. The optimized SVM method has certain advantages for vehicle lane-changing decision-making with a small sample size in actual production processes. The lane-changing decision judgment accuracy rate of the SSA-SVM algorithm model can reach 93.6% compared with the SVM algorithm model without algorithm optimization; the SSA-SVM algorithm model has obvious advantages in decision performance and running speed. Therefore, the proposed new algorithm can effectively solve the problem of the objective consideration of the payoff function in conventional decision game theory.

Optimizing flotation froth image segmentation via parallel branch network and hybrid loss supervision

Flotation is a crucial technology for fine coal separation, and accurately acquiring bubble size information during the flotation process is essential for monitoring flotation conditions and achieving intelligent control. However, existing semantic segmentation models encountered issues with boundary disconnection when segmenting flotation bubbles, resulting in deviations between the extracted bubble sizes and their true values. To address the aforementioned challenges, a semantic segmentation model was proposed to maintain high-resolution feature maps throughout the network by designing a parallel branch network structure. Additionally, a ConvTranspose module was proposed to preserve the detailed feature information of images while gradually enhancing the resolution of feature maps. In the model training phase, a hybrid loss function combining pixel classification loss with shape similarity loss was proposed to alleviate the sample imbalance problem caused by the substantial difference in the number of pixels between bubble boundaries and the interior of bubbles. Moreover, since traditional semantic segmentation evaluation metrics, such as MIoU, lack a mechanism for measuring bubble boundary continuity and cannot effectively penalize the problem of boundary disconnection, this paper proposed a new evaluation method for assessing the segmentation performance of flotation froth images. To comprehensively evaluate the effectiveness of the proposed method, this paper conducted tests using flotation froth images collected from actual production processes. Compared with existing methods, the segmentation model proposed in this paper exhibited clear superiority in mitigating the problem of bubble boundary disconnection. The prediction error for the number of bubbles was 6.38 %, which is significantly better than other methods.

Simulation Experiment Research on the Production of Large Box Girders

This paper introduces system simulation technology into large-scale beam field production and uses the simulation software Arena (14.0) to construct a simulation model of the beam field production system considering the randomness of the actual beam field production process operation time. The relationship between the production efficiency of the beam yard and the working time system was studied. In this paper, the improvement in beam-making efficiency in the existing beam field that is achieved by the commonly used reinforcement pre-binding method in the existing beam field is analyzed and calculated, and the improvements in the production efficiency in the ordinary beam field and the intelligent beam field are quantitatively calculated and compared. The results show that (1) when the working time system is increased from 8 h/d to 12 h/d, the average occupancy time of the traditional beam-making pedestal is shortened by 11.5 h when the working time is extended by 1 h per day; (2) with the extension of the working time system, the advantages of the pre-binding method of reinforcement gradually decrease; and (3) the application of intelligent technology not only improves the production efficiency of the beam yard but also makes the beam yard’s production more flexible and more resistant to risks.

거시경제학의 근본적인 문제점: 항등식을 인과성으로 사용

GDP, which only measures the value of the final product, ignores the various production processes that take place in the real world before the final product is produced. In this sense, GDP is not a reflection of the real world, but rather an artificially constructed measure of a ‘fictitious economy’. A bigger problem with GDP is that the identity equation, by which GDP is expressed as the sum of consumer spending, business investment spending, government spending, and net exports, is used in a causal way. Using this identity equation, governments often implement policies that increase spending to stimulate the economy and grow the economy. However, the principle of human behavior that one must first produce in order to consume implies that production is the cause and consumption is the effect. The idea, which implies that consumption is the cause, is thus incorrect because it goes against the principle of human behavior. This idea is based on Keynes's theory. Keynes's theory, as presented in his General Theory, is a misinterpretation of Say's Law of the Market, which states that “when one product is produced, it creates a demand for another product,” as “supply creates its own demand.” Macroeconomics, which was started based on the wrong Keynes' theory, is also a theory that is far from the real world and does not explain the economic problems that are occurring in the real world, such as the financial crisis. Therefore, in order for macroeconomics to properly explain the real world, it is necessary to establish a new macroeconomics. The new macroeconomics should be based on the principles of human behavior and should include the actual production process and the activities of entrepreneurs, who play an important role in the production process. The Austrian Business Cycle Theory, which covers these aspects, can serve as the cornerstone of a new macroeconomic theory.

Multi-line laser 3D reconstruction method based on spatial quadric surface and geometric estimation

The traditional multi-line laser 3D reconstruction is based on binocular epipolar constraints and the equation of the laser optical plane. Firstly, matching points are identified based on the epipolar constraints. Then, the correct matching points are selected based on the optical plane equation of the multi-line laser. Finally, 3D reconstruction is performed using the selected matching points. In actual production processes involving multi-line lasers, noticeable distortion occurs due to the projection of Diffractive Optical Elements (DOE) at a large angle. This results in curved laser light planes and curved reflections on the measured objects. Under such circumstances, efficiently screening matching points using the traditional method based on the laser plane equation becomes challenging. Additionally, inherent noise in multi-line laser systems introduces errors in extracted laser center coordinates, making it impossible to directly obtain high-precision 3D data. To address these issues, this paper proposes a method that utilizes spatial quadric surfaces and geometric estimation for completing multi-line laser 3D reconstructions. By analyzing the distortion principle of DOE and the positional relationship after optical diffraction, the multi-line laser manifests as a quadric surface on the optical output plane. Consequently, by calibrating the equations of the quadric surface and applying binocular polar constraints, suitable matching points for the multi-line laser can be chosen. Once an accurate matching point is identified, a minimum geometric distance estimation can be established based on the distance constraint between the point and its corresponding epipolar line. This distance represents the separation between the left and right camera’s laser center points and their respective epipolar lines. Utilizing this estimate of the minimum geometric distance, a refined calculation can be performed to better satisfy epipolar constraints and obtain new matching points. Ultimately, utilizing these new matching points enables the completion of 3D reconstruction for multi-line lasers. In comparison with methods relying on spatial plane and epipolar constraints, our algorithm exhibits a superior degree of matchability and accuracy.According to multiple groups of test data, the average error before optimization is 0.3126 mm, and can be increased to 0.0336 mm after optimization.

Discrimination of brewing technologies and assessment of health risks based on rare earth elements: Evidence of fingerprint in Chinese famous vinegars

Considering the essential influence of vinegar brewing processes on human health, this study determined the content and fractionation of rare earth elements (REEs) in 40 Chinese vinegar products to assess food safety and probe the application of REEs in tracing brewing processes. The total REEs contents in different products exhibited great variations (1.66 μg/kg to 124.54 μg/kg), which should be attributed to the difference in brewing techniques. Vinegars produced by solid brewing fermentation normally contain higher REEs contents than those produced by liquid brewing fermentation. The REEs contents in vinegars from inland areas were higher than those from coastal areas. The health risk assessment indicated that REEs contents were below the daily intake standards; however, considerable attention should be paid on the risk to children. This study contributes foundational data for understanding REEs behavior in vinegars, which is crucial for ensuring food safety and identifying the actual vinegar production process.

Continuous cooling transformation in micro-alloyed medium-carbon steel and optimization of the forging process for half-shaft production

Abstract Micro-alloyed medium-carbon steel is increasingly used as a cost-effective alternative to quenched and tempered steel in the production of half-shaft components. Current research emphasizes controlling the microstructure during thermomechanical processing to achieve the desired structural properties after cooling. This study investigated the effect of continuous cooling transformation on the microstructure and mechanical properties of micro-alloyed medium-carbon steel. At a cooling rate of 0.5 °C s−1, only pearlite transformation occurred. At rates between 1 °C s−1 and 8 °C s−1, both bainite and martensite transformations were observed, while only martensite formed at rates exceeding 12 °C s−1. Subsequently, a four-factor, three-level orthogonal experiment was designed based on the actual production process for half shafts. The optimal forging parameters were identified as a heating temperature of 1000 °C, a deformation temperature of 920 °C, a deformation extent of 15%, and a cooling rate of 0.5 °C s−1. The study offered solutions to enhance microstructural uniformity and effectively manage abnormal bainite and martensite formations, thereby establishing a foundation for the high-quality application of micro-alloyed medium-carbon steel in half-shaft components.

Investigation of the polysaccharides synthesis enhancement mechanism from Agaricus bitoquis (Quél.) Sacc Chaidam and its fermentation regulation technology system based on multi-omics technologies

The polysaccharides (PS) of Agaricus bitoquis (Quél.) Sacc. Chaidam (ABSC) had attracted the attention of researchers due to their strong anti hypoxia, antioxidant, and anti fatigue activities. Therefore, this article focuses on studying the regulatory channels of exogenous additives-Lycium ruthenicum Murr. Anthocyanin (LRA) to delay fungus cell aging and promote the incremental synthesis of PS from ABSC, and optimizing the regulation system for pilot fermentation experiments. The joint analysis of Ultra High Performance Liquid Chromatography-Quadrupole-Time of Flight Mass Spectrometry (UHPLC-Q-TOFMS) and RNA sequencing (RNA-seq) database elucidates that at the molecular level, the crude extract of LRA inhibits the Telecommunications Association (TCA) cycle, transferring carbon metabolism to the synthesis of polysaccharide precursors (UDP-glucose, UDP-galactose, etc.), promoting the synthesis of PS, promoting the formation of key antioxidant substances (including flavonoids such as quercetin and alginate), improving cell membrane fluidity (saturated fatty acid to unsaturated conversion) and enhancing the degradation of toxic substances (oxidized glutathione), thereby promoting the anti-aging activity and PS synthesis ability of mycelial cells; LRA-adding could enhance the activity in the pilot fermentation of ABSC, which make the mycelia biomass, EPS and IPS production were significantly increased (89.04 %, 65.46 % and 37.64 % respectively) compared with the untreatment control. Based on the optimal fermentation system of PS synthesized in mycelium by adding LRA, Logistic, Gauss, and Asymptotic kinetic equations were used to describe the cell growth, product synthesis and regulatory substrate consumption from ABSC. The correlation coefficients of three models were all above 0.95, indicating a good fit between the experimental values and predicted value, this indicated ABSC fermentation kinetics model could better simulate the actual production process and provide theoretical data for the industrial production of polysaccharides. The results demonstrated that the present proposed LRA intensification approach could be useful to boost up the fermentation of ABSC, which possibly applied to yield increase and fermentation product acquisition of macrofungi.

Addressing multi-step inverse heat transfer problems via reduced order models in a cooling process for polymer pipes with sparse measurements

In modern polymer pipe extrusion processes with connected post-processing steps, the intermediate cooling and conditioning process is essential for the resulting product quality. In such cases, computationally efficient models are required for real-time process control and optimization. Unfortunately, heat transfer coefficients are rarely known for actual production processes, leading to an inverse heat transfer problem. Existing methods mainly rely on computationally intensive numerical models or on data intensive neural networks. Both are not suitable, if only sparse measurements are available and a fast execution time is required. In contrast to that, we propose to use a proper orthogonal decomposition and project the governing heat equation onto extracted basis functions via the Galerkin method. This leads to an efficient and accurate reduced order model, which can be used for parameter identification and subsequent process control. Regarding the identification, we address the ill-posed problem with well-known relative constraints, l2 regularization and decomposition of coefficients based on the Nusselt number. Simulation and experimental results show that the heat transfer coefficients are consistently identified and robust against initial parameter guesses despite sparse and noisy temperature measurements. Consequently, the proposed method can be efficiently applied in cooling and conditioning processes in polymer extrusion and related applications such as identifying the heat transfer coefficients and thermal resistance in pressurized surge lines of nuclear power plants and brick walls in melting furnaces respectively.

Phospholipid biosynthesis regulation for improving pigment production by Monascus in response to ammonium chloride stress.

In the actual industrial production process, the efficient biosynthesis and secretion of Monascus pigments (MPs) tend to take place under abiotic stresses, which often result in an imbalance of cell homeostasis. The present study aimed to thoroughly describe the changes in lipid profiles in Monascus purpureus by absolute quantitative lipidomics and tandem mass tag-based quantitative proteomics. The results showed that ammonium chloride stress (15 g/L) increased MP production while inhibiting ergosterol biosynthesis, leading to an imbalance in membrane lipid homeostasis in Monascus. In response to the imbalance of lipid homeostasis, the regulation mechanism of phospholipids in Monascus was implemented, including the inhibition of lysophospholipids production, maintenance of the ratio of PC/PE, and improvement of the biosynthesis of phosphatidylglycerol, phosphatidylserine, and cardiolipin with high saturated and long carbon chain fatty acids through the CDP-DG pathway rather than the Kennedy pathway. The inhibition of lysophospholipid biosynthesis was attributed to the upregulated expression of protein and its gene related to lysophospholipase NTE1, while maintenance of the PC/PE ratio was achieved by the upregulated expression of protein and its gene related to CTP: phosphoethanolamine cytidylyltransferase and phosphatidylethanolamine N-methyltransferase in the Kennedy pathway. These findings provide insights into the regulation mechanism of MP biosynthesis from new perspectives.IMPORTANCEMonascus is important in food microbiology as it produces natural colorants known as Monascus pigments (MPs). The industrial production of MPs has been achieved by liquid fermentation, in which the nitrogen source (especially ammonium chloride) is a key nutritional parameter. Previous studies have investigated the regulatory mechanisms of substance and energy metabolism, as well as the cross-protective mechanisms in Monascus in response to ammonium chloride stress. Our research in this work demonstrated that ammonium chloride stress also caused an imbalance of membrane lipid homeostasis in Monascus due to the inhibition of ergosterol biosynthesis. We found that the regulation mechanism of phospholipids in Monascus was implemented, including inhibition of lysophospholipids production, maintenance of the ratio of PC/PE, and improvement of biosynthesis of phosphatidylglycerol, phosphatidylserine, and cardiolipin with high saturated and long carbon chain fatty acids through the CDP-DG pathway. These findings further refine the regulatory mechanisms of MP production and secretion.

Chemical plant optimization layout based on the domino hazard index considering the fixed hazard unit outside the available area

The layout of chemical plants is a significant step to promote the safe and efficient operation of a chemical factory. In the actual production process, the chemical process plant layout may be affected by immovable hazards outside the available layout area. In this paper, the external hazard unit is arranged as one of the chemical process plants. The domino effect potential of all chemical process plants is quantified by using the classical domino hazard index (DHI). A layout optimization model considering the effects of external hazard units has been proposed to obtain the optimal plant layout from economic and safety aspects. The feasible layout solutions are obtained under the orientation, boundary and non-overlapping constraints by the non-dominated sorting genetic algorithm II (NSGA-Ⅱ). The proposed model is further analyzed through a hypothetical case of three storage tanks outside the acrylic acid (AA) production plant layout area. The results show that the total cost range for the optimal solution is 650348–1365443 $, with corresponding DHI values ranging from 29 to 129. The plant with larger DHI value will be arranged to far away from the external hazard units to obtain a safer layout. This work can provide rational layout solutions for the layout designers to make different decisions according to the actual situation.

Simulation Model of a Steelmaking-Continuous Casting Process Based on Dynamic-Operation Rules.

The steelmaking-continuous casting process (SCCP) is a complex manufacturing process which exhibits the distinct features of process manufacturing. The SCCP involves a variety of production elements, such as multiple process routes, a wide array of smelting and auxiliary devices, and a variety of raw and auxiliary materials. The production-simulation of SCCP holds a natural advantage in being able to accurately depict the intricate production behavior involved, and this serves as a crucial tool for optimizing the production operation of the SCCP. This paper thoroughly considers the various production elements involved in the SCCP, such as the fluctuation of the converter smelting cycle, fluctuation of heat weight, and ladle operation. Based on the Plant Simulation software platform, a dynamic simulation model of the SCCP is established and detailed descriptions are provided regarding the design of an SCCP using dynamic-operation rules. Additionally, a dynamic operational control program for the SCCP is developed using the SimTalk language, one which ensures the continuous operation of the caster in the SCCP, using the discrete simulation platform. The effectiveness of the proposed dynamic simulation model is verified by the total completion time of the production plan, the transfer time of the heat among the different processes, and the frequency of ladle turnover. The simulation's results indicate that the dynamic simulation model has a satisfactory effect in simulating the actual production process. On this basis, the application effects of different schedules are compared and analyzed. Compared with a heuristic schedule, the optimized schedule based on the "furnace-machine coordinating" mode reduces the weighted value of total completion time by 8.7 min, reduces the weighted value of transfer waiting time by 45.5 min, and the number of rescheduling times is also reduced, demonstrating a better application effect and verifying the optimizing effect of the "furnace-machine coordinating" mode on the schedule.

The Removal of Endotoxins in the Actual Production Process

Endotoxins, also called lipopolysaccharides (LPS), are mostly found in the outer membrane of Gram-negative bacteria, which are widely used as a common expression system to produce some biological products. The presence of small amounts of endotoxin can cause side effects in host organism such as endotoxin shock, tissue injury, and even death. Due to these reactions, it is essential to remove endotoxins in the final products. In the actual production process, endotoxin contamination can occur at any process unit. In this article, we review the structure and characteristics of endotoxins and the effects that it causes in vivo. The endotoxin removal strategies are also elaborated according to the relevant mechanism. Besides, the endotoxin removal also faces enormous challenges in the actual production process.

Dynamometer card generation for pumping units based on CNN and electrical parameters

In the actual production process of oil fields, the real-time and accurate acquisition of dynamic recorder data from the pumping unit is of great significance for the diagnosis of well failures. The traditional method of obtaining the card of the dynamometer usually includes installing a load sensor on the auxiliary head of the pumping unit. However, due to the harsh environment of the oil field production site, these load sensors often suffer from damage, distortion, and aging, resulting in large measurement errors and low reliability. This paper proposes a mixed model of pumping based on motor electrical parameter data and CNN convolutional neural network, which has good consistency with actual data in terms of predictive performance. Thus, the highlights of this paper can be summed up in two points: (1) Based on the mathematical model of the AC motor, the speed of the motor and the torque output of the motor are accurately estimated. (2) The convolutional neural network is introduced to compensate for the errors caused by the defects of the pumping unit mechanism model.

Moderate Drought Stress Interferes with the Physiological State and Promotes the Accumulation of Isoflavone in Reproductive Iris domestica Rhizomes

Drought stress is one of the main factors affecting the growth and secondary metabolism of plants. Iris domestica, rich in isoflavones, is a common herbal medicine in China. In this study, the effects of drought stress and rehydration on resistance physiological characteristics and the secondary metabolism of two-year-old I. domestica during the vegetative and reproductive growth period were investigated. The results showed that the dry weight and fresh weight of rhizomes and roots under severe drought stress were significantly decreased, while those under moderate drought stress were not significantly changed. Meanwhile, the SOD activities, POD activities, MDA content and Pro content increased to resist drought at D1 and D2. In the vegetative growth period, the changes in isoflavone concentration and the expression levels of genes in isoflavone synthesis were more dramatic. Isoflavone accumulation was promoted, to some extent, in the reproductive growth period under the D1 drought treatment. In the actual production process, different measures, namely short-term stress regulation in the vegetative growth period and moderate drought stress (13.44% < soil water content ≤ 16.8%) in the reproductive growth period, need to be adopted to regulate isoflavone biosynthesis.

High‐Temperature Heat Pumps for Industrial Use

AbstractCompared to heat pumps established in the building sector, high‐temperature heat pumps (HTHPs) suitable for industrial use still face challenges, not only from a mechanical engineering point of view but also regarding integration into existing processes. They need to supply larger amounts of heat at higher temperatures. The mere replacement of a gas boiler by an HTHP will rarely deliver an energy‐efficient solution. Instead, these units must often be tailored to the application and vice versa, making specifications a complex task. This paper intends to link thermodynamic and economic basics of HTHPs to the process engineering of the actual production process. It also ventures an outlook on the economic and regulatory boundary conditions in the EU as corner stones for a sustainable investment decision.

The Effect of the Proportion of Rubber Components on the Properties of EVA/SBR/BR Foams

In actual production processes, pure ethyl vinyl acetate (EVA) foams have a high shrinkage rate, and the foaming matrix is prone to plastic deformation, even causing the collapse of bubbles. This limits the further application of EVA foams. In this study, we incorporated styrene butadiene rubber (SBR) and butadiene rubber (BR) into EVA to improve the mechanical properties and dimensional stability of EVA composite foams without sacrificing their low-density characteristics of low density. We used a melting index meter, rotorless vulcanizing meter and dynamic mechanical analysis (DMA) to characterize the changes in viscosity and energy storage modulus of the composite matrix. Scanning electron microscopy (SEM) was used to study the microscopic morphology of foams. The mechanical properties test results showed that the addition of SBR reduced the density of EVA/SBR/BR composite foams, and the addition of BR improved the mechanical properties and dimensional stability of the foams. By combining the advantages of both, the density of products is comparable to pure EVA, the tensile strength and the compressive strength are increased by 11% and 6.3% relative to pure EVA, respectively.

Sustainable Cultivation of Discipline Competition Programs for Innovation and Entrepreneurship Education: An Example of the Food Science and Engineering Major

Cultivating innovative and entrepreneurial talents has become the responsibility and mission of higher education. It reflects the effectiveness of education in terms of teaching quality, scientific prowess, and social service. Discipline competitions played a significant role in fostering innovation and entrepreneurship ability, serving as a crucial component of innovation and entrepreneurship education in colleges. This study used the food science and engineering major as an example to address the gap between theoretical knowledge teaching and the actual production process. It aimed to improve the poor performance of innovative practices by establishing a sustainable cultivation model for discipline competition programs. There needs to be an investigation into the conduct of disciplinary competitions and the students’ participation in them. Then, a model comprising a “theory + experiment + practice” course to guide students in participating in competitions should be formed. A rational and sustainable innovation team and a collaborative innovation platform for school–enterprise integration needs to be built. In order to achieve sustainable development education and cultivate applied talents who can solve complex problems in food engineering, the sustainable cultivation model was established. This work could serve as a reference for developing professional discipline competitions and fostering innovative and entrepreneurial talents for sustainable development.